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

  1. #481
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Been a bit slow in the garage of late.

    Decided to go Quaife ATB and use the SKF bearings, no point being half arse.

    IMG_3059.JPG


    Took it to Road and Race in Kent to fit it all. All new bearings and seals in the diff, along with a full check of the crown and pinion, which was found in excellent condition

    IMG_3562.JPG

    IMG_3142.JPG
    I've seen people having issues with the cheaper bearings slipping off because the keeper ring slips The SKF bearings keeper rings were heated up for fitting. If they just press on, then it makes sense they can slip off.

    Road and race also supply a specific oil for the ATB. Overall great service at a sensible price.

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

    Axel now complete

    IMG_3563.JPG
    Housing flange cleaned up

    Wiped out the housing to make sure there's no dust of crap got in there, followed by a squirt of the diff oil wiped around to prevent any surface corrosion as it's going to be a while before the oil gets splashed about in there
    IMG_3564.JPG

    Done, all torqued up, with half shafts and diff tag fitted
    IMG_3565.JPG

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

    This little lot back from the metal platers

    IMG_3145.JPG
    Really pleased with all of this, especially the bonnet locking pin as I extended this a while back in the tread by welding a bolt on, and there's sign of it.

    IMG_3144.JPG

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

    Taking shApe nicely, hopefully painted this year :-)))

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

    Hi Donnie, unfortunately I’m not sure about getting the paint done this year now, which was the plan.
    Redundancy caught up with me so until I’m sorted spending on the car has to take a back seat. Still got loads to crack on with. I’ll do another little update soon on the engine, I’ve started on the front suspension and the wiring loom is waiting for some attention
    You been putting some miles on your Escort over the summer?

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

    Sorry to hear about being made redundant as it’s challenging times. As for the RS, bee, having a blast, problem being the limited time but she got a good using and enjoyed every minute of it

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

    Quote Originally Posted by donnie View Post
    Sorry to hear about being made redundant as it’s challenging times. As for the RS, bee, having a blast, problem being the limited time but she got a good using and enjoyed every minute of it
    Thanks Donnie, I’ll get sorted. It’s surprising how little time I’ve had despite the situation. Anyway progress is being made and that’s most important. Good to hear you’ve put some miles on yours ����

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  9. #488
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    2.0L Zetec E Black Top strip down

    Time to crack on with the engine. I started cleaning the block, getting the worst of the crap off it before removing the head. I'd cleaned all the oil and grease off back when I got it. (previous post)
    IMG_3099.JPG

    IMG_3100.JPG

    With the head off I found some light water marks on the cylinders, other than that the the bores are in really good order, but they need to be honed.
    IMG_3224.JPG

    Found some of the piston rings seized and 2 oil rings where snapped. Probably due to being sat for a long time.
    IMG_3230.JPG
    IMG_3231.JPG

    Crank looks good to.

    IMG_3234.JPG

    IMG_3235.JPG
    Interestingly I found a big scratch in one of the big end bearings (second one down in the pic below) just one half, but no marks on the crank or the other bearing half, thankfully. This must have happened before it was fitting in the factory, so much for QA.
    IMG_3233.JPG

    Having stripped the engine it's been taken off to an engine shop, recommended for Zetec work, by a race engine shop, which only do full builds, I want to do most of the rebuild myself.
    Initial plan is they will clean it, properly check/measure everything and hone the cylinders, strip the head, re cut the valve seats and rebuild the head. I decided it wasn't worth doing myself as I'd have to get a new valve spring compressor, and mess about with shimming.

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

    Engine shop found every thing in good order except the cylinder water marks, which after honing are still visible.
    Options where :- 1. leave it and see how it goes. 2. Hone it more and have a bit of slap in the pistons. 3. re-bore and fit over sized pistons.
    Option 3 it is.
    Finding the over sized pistons was a bit of a pain as I didn't want to pay for racing pistons.
    Found these at ovalracingshop.co.uk They are made for a race class where the engines can't be modified
    Pistons, Rings and gudgeon pins £75 each. so an unplanned £300 but I don't want to be going back to re do it later.
    Really nicely packaged with the rings all labelled along with fitting instructions on the wrapping

    IMG_3763.JPG

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

    Cylinder head Before
    IMG_E3223.JPG


    and After

    IMG_3766.JPG

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

    Fitting the bonnet stay, that's a five minute job......

    IMG_3764.JPG

    Turned into a real pain in the arse. The stub wasn't clearing the inner wing, so I've had to cut the stub and knock the inner wing back a little, not at all easy.
    If you're fitting a slam panel make sure you check the clearance. The hole for the stay grommet in mine was off set too the outside compared to the original. A little detail I missed. This also effects the alignment with the hole at the near side where the stay clips in when stowed.

    IMG_3765.JPG
    Under the slam panel after sorting the problem. The tape is the PTF panel tape used else where as panel protection
    Last edited by Zakspak; 17-09-2022 at 22:44.

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

    No such thing as a 5 minute job on a classic :-)))

    Engine rebuild worth it as you then know you have something reliable

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

    Quote Originally Posted by donnie View Post
    No such thing as a 5 minute job on a classic :-)))

    Engine rebuild worth it as you then know you have something reliable
    totally agree on both Donnie, and i should have learned long ago there's no 5 min jobs

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

    Making a start on the loom. Everything labeled up.
    There's circuits to remove such as the "Dual break warning indicator" and conventional "ignition" and others to add for the ECU. Overall condition check and some modifications to make.
    This is just the front section minus the headlight sections.
    IMG_3956.JPG

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

    Engine collected today.
    First job will be to paint the block, breather and oil cooler, for now its all oiled and boxed up, whilst I sort out gaskets, bearings, water rail, oil and water pump.

    IMG_3968.JPG

    IMG_3966.JPG

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

    Funny looking BDG? - must be a racing one LOL!

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

    They did a little work to the head, maybe more than planned ��

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

    Hey friend, is there any progress in the renovation of your Escort? Tanks tom

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

    My first time back on Turbosport for years, and I've just spent ages getting lost in reading this thread. You really are doing a fantastic job. Top work!

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

    Thanks Jon and hopefully you'll be back more. This is a great resource.
    I really appreciate you taking time to look at what I'm doing
    Cheers

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

    End of year update. Unfortunately not as productive as I'd hoped or thought. I really believed I'd finish this year, but it wasn't to be.

    Front struts, Brakes.
    I put these together back in September, but I was waiting on a detail before posting
    These are original RS2000 legs and I'm using Gaz adjustable inserts
    There's 2 types of Gaz inserts for the Mk2 escort, so make sure you get the right one. The RS legs require the shorter inserts. Then depending on the top mount you also need certain sleeves. Burton Power directed me on all this.
    I had all the parts blasted and powder coated a couple of years ago (way back in the build thread)

    IMG_3758.JPG

    IMG_3953.JPG

    These are the original inserts from the bottom of the legs. They weren't required for my legs, but if you're doing this job don't bin them until you're sure. Not all RS legs are the same
    IMG_3776.JPG
    Last edited by Miniliteman; 31-12-2022 at 21:10.

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

    The inserts drop in and the securing nut winds down to become flush and tight. I oiled the inside with a silicon before putting this all together to prevent corrosion
    IMG_3759.JPG

    The springs originally has a plastic sleeve on each end, this was a but worn so I reinforced it with a PVC heat shrink
    IMG_3952.JPG

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

    Leg assembly

    IMG_3954.JPG

    Spherical bearing top mounts.
    IMG_3955.JPG

    Steering arms attached
    IMG_3907.JPG

    Dust covers Come back to this
    IMG_3903.JPG

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

    Hubs and vented discs

    IMG_3818.JPG
    All new bearings, tab washers and bolts.
    The bearing covers, washers, nuts and lock caps are original

    IMG_3829.JPG

    IMG_3830.JPG

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

    Callipers with vented disc modification.

    IMG_E3819.JPG
    New stainless steel pistons and seal kit

    IMG_E3825.JPG

    IMG_E3826.JPG

    IMG_E3827.JPG

    IMG_E3831.JPG

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

    Legs complete

    IMG_4692.JPG

    No brake disc dust covers...... they don't fit with the vented disc callipers. I buggered about for some time trying to make them work.

    IMG_4689.JPG

    Having put them together I wanted some detail. The Ford/Sach reproduction decals didn't seem appropriate, so a call to Gaz, and an email to DMB graphics, but I only got around to putting them on today.
    IMG_4691.JPG

    IMG_4690.JPG

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

    Update on the wiring loom to follow
    Happy New Year gents

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

    Taking shape and Happy New Year to you

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

    Thanks Donnie, same to you to.
    Not sure about taking shape, I’ve haven’t achieved much at all over the last 3-4 months. So fingers crossed circumstances will allow some proper progress over the next few months ����

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

    Wiring loom and first update of 2023
    Back in Sept I got the loom out, cleaned and labelled it. Since then I've put in a fair few hours. The loom seemed in good condition, but because of the modifications it needed to have all the tape removed. I would have done that anyway as it's was well worth it. Just a few pics here as it's fairly repetitive stuff, but I've done a lot of work.
    IMG_4051.JPG

    With the tape off, the wiring was wiped down with white spirit to remove the glue and 40 years of dirt. Cable ties hold it together allowing cables to be removed and new ones fitted at the same time as being able to inspect each wire

    This was fairly obvious. Its the horn wire and wasn't under tape. Not too big a worry
    IMG_4052.JPG

    The loom bundle, just beyond the bulkhead grommet.
    IMG_4102.JPG
    The red cable is the main Positive feed from the alternator, it taps off to the battery further down, Red/Blue, another main feed to the fuses. They're imbedded in the loom bundle. All except maybe 3 of the wires insulation around this cable was in the same condition, snap brittle as you can see, the only one I've touched at this point is the Green/Black removing that small section. The conductors were fine, no signs of overheating or hardening. There was some discolouration on some of the insulation, but only a little. The effected section was only over about 15cm.
    Fortunately I'm making significant modifications so most of the effected wires are replaced, saving splicing in repairs.
    I would think the loom has been getting hot in this section, for long periods of time rather than a short intense heating. Why I'm not sure.


    The point here is "don't assume your old loom is in good order"

    On the rear section I've found various points of damage to the insulation, with some signs of arcing. The damage looked like it was due to snagging/pulling or crushing on the sharp edges around the rear light metal work.

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

    Quote Originally Posted by Zakspak View Post
    I would think the loom has been getting hot in this section, for long periods of time rather than a short intense heating. Why I'm not sure.
    Maybe it was the resistor-wire for the ignition.

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

    Loom modifications :-
    Headlights are being run via separate fused relays. Dip, Main and auxiliary.
    Front Spot/fog lights run via fused relay
    Separate main alternator feed from stud connection to Starter motor where it will feed back to the battery (using the starter motor stud as a terminal point)
    New integrated alternator feed from alternator plug spliced into the loom.
    Electric fan supply run via main fuse
    Oil pressure light and electrical gauge feeds added (Not included on the RS loom due the capillary oil gauge)
    Dash RS light (not normally illuminated) connected to the instrument illumination.
    New horn wire
    New side light wires
    Time delayed heated rear window, run from modified brake warning switch
    Rev counter circuit installed to run from the coil pack. (ECU feed is a +Ve and wont run the original tacho)
    Rear fog light
    ECU loom integrated, and modified to put the fuel pump relay/fuse in the boot with the battery.
    Uprated negatives/returns
    Dash supplies added for options such as USB charge adaptor.
    Various redundant wires removed, Ignition, Head lights, Brake circuit warning, Battery feed, Alternator supply

    There's probably some bits I've missed.

    All the new cabling is done in Thin wall colour coded wire, and each circuit has been calculated for current and volt drop. One delay factor has been planning and then ordering cable and fittings.

    Fuses re-purposed. Radiator fan run from "ignition on" fuse via fan switch in thermostat housing.

    IMG_4108.JPG

    IMG_4109.JPG
    Last edited by Zakspak; 01-01-2023 at 23:44.

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

    Quote Originally Posted by Miniliteman View Post
    Maybe it was the resistor-wire for the ignition.
    This loom doesn't use a resistance wire

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

    I used a spare hazard switch to repair a damaged on/off switch (Think that was a heated rear window switch)
    These are fairly easy to strip down and worth doing to clean up the internal contacts but care is needed as the mechanisms are all plastic.

    IMG_4218.JPG

    IMG_4219.JPG

    IMG_4220.JPG

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

    ECU loom
    This is made to be plug and play, by cutting a new 50mm hole in the bulkhead and connecting into the positive and negative feeds in the engine bay.
    To integrate it the main plug has to come off. Easy enough just make sure all the wires are labelled to their position, I backed this up with some photos and a drawing
    ECU plug on the left, fuel pump relay on the right
    IMG_4315.JPG

    IMG_4318.JPG

    Then the Fuel pump control relay and fuse section was stripped and wires extended to put it in the boot, and the loom was fed through the original bulkhead grommet
    IMG_4319.JPG

    IMG_4331.JPG

    Positive and negative feeds to be made inside the under the dash.

    I've still got repairs to make to the rear section of loom to the damaged wires, one of which I'll probably just re run with a spare I have from another loom. The next job on the front section is to put it in the car to work out fixing points. All final terminations will be done with the engine in, so I'll be starting putting that back together before long.
    That's it for now

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

    A lot of work, very tidy and satisfying when done :-))

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

    Front wiring loom

    Original loom in sept 22
    IMG_3956.JPG

    Updated front loom as of today
    IMG_4716.JPG

    The "spaghetti" on the lower left is the various coils to extend to the rear and boot for the ECU fuel pump control and rear fog light. Also in there is the ECU loom and plug.
    The lighter coils above are the front light cabling, relay triggers, supplies and loads
    Along the bottom is the dash cabling, various switches and controls, upgraded, repaired and new systems switching controls, along with original wiring. I've started putting mesh sleeving on some of this.
    Above on the right is the ECU engine control, injectors, coil pack etc as well as fan control and electrical oil indication.
    Looping around the top is the alternator cabling (minus the main charging cable), horn, washer bottle and RH lighting.

    I'll be trimming and terminating the ends when the looms in the car which should be soon as I'm making time to get back on it and re focus.
    Hopefully more to follow soon

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

    Quote Originally Posted by Zakspak View Post
    Front wiring loom

    Original loom in sept 22
    Attachment 88364

    Updated front loom as of today
    Attachment 88365

    The "spaghetti" on the lower left is the various coils to extend to the rear and boot for the ECU fuel pump control and rear fog light. Also in there is the ECU loom and plug.
    The lighter coils above are the front light cabling, relay triggers, supplies and loads
    Along the bottom is the dash cabling, various switches and controls, upgraded, repaired and new systems switching controls, along with original wiring. I've started putting mesh sleeving on some of this.
    Above on the right is the ECU engine control, injectors, coil pack etc as well as fan control and electrical oil indication.
    Looping around the top is the alternator cabling (minus the main charging cable), horn, washer bottle and RH lighting.

    I'll be trimming and terminating the ends when the looms in the car which should be soon as I'm making time to get back on it and re focus.
    Hopefully more to follow soon
    Hi friend, question does your car have spacers in the back and front?

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

    Quote Originally Posted by Tom escort mkii View Post
    Hi friend, question does your car have spacers in the back and front?
    Hi Tom, no I’ve never run the car with spacers, the wheels fill the arches and clear the running gear. I’m running 13”x 8” rims on the front and 13”x 9” on the back with the correct offset (I do t remember what that is). If you look back through the tread you’ll see details of the wheels.

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

    Quote Originally Posted by Zakspak View Post
    Hi Tom, no I’ve never run the car with spacers, the wheels fill the arches and clear the running gear. I’m running 13”x 8” rims on the front and 13”x 9” on the back with the correct offset (I do t remember what that is). If you look back through the tread you’ll see details of the wheels.
    Can I give you my email to talk to you? Please this is my email tombaron300@gmail.com I would be happy to contact me I want to ask a few things

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