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

  1. #561
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    ECU temperature sensor.

    The Omex ECU sensor (standard Ford Zetec part) has an M12x1.5 thread so I tapped this in the top. Same measuring and drilling process.
    The ECU sensor can use PTFE tape (recommend by OMEX) it also has an O ring seal, and due to it's size I didn't use an adapter, going straight into the casting.

    IMG_5971.JPG

    IMG_5973.JPG


    Fitted to the Head.
    IMG_5976.JPG

    IMG_5977.JPG

    IMG_5979.JPG
    Here you can see the 2 rear sensor tappings, (plugged) and the crank breather pipe I made up fitted.

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

    The support bracket I made up for the front of the water rail, I just wasn't happy with. It was far too clunky.
    On the right, support No1 and on the left "take 2" which I'm much happier with. It's about half the weight of the first support and is a lot less clunky & home made.

    IMG_5954.JPG

    IMG_5978.JPG

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

    Just a note, the people at Raceline were really helpful with discussing options and methods for modifying the water rail for the sensors.

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

    You've documented pretty much the same 'stumbles' I found using the Raceline rail. When I asked about the front support, Raceline hadn't heard of that problem ! so I came up with a similar strap arrangement - not pretty but functional LOL! I too liked / preferred the RL rail and yes the limited drillings was a problem also - I put the ECU sensor into the thermostat housing as a solution. The thing that I couldn't live with (in an escort at least) was once the RL rail was fitted - and it has to be before the head / engine is in the car - I couldn't fit the ex. manifold, there just wasn't the space! I had to lift the head just to fit the manifold which I found un-acceptable so I swapped to a RetroFord rail just for the ease of access etc. I wise i'd kept the Ford crankcase vent but that went in the bin years before the engine got built and any subsequent vent arrangement has leaked - bugger!

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

    Raceline now supply a front support bracket but I thought it was expensive for what it is.
    I thought about putting the ECU sensor in the thermostat housing or the front hose, but the instructions said it has to be pre thermostat. Another reason for putting it at the back was it’s picking up the water temperature as close to the block outlet as possible, in case that makes any difference.
    Re the exhaust, you mentioned it before. I found during dry fitting the engine I couldn’t get the exhaust manifold on (Retro Ford 4-2-1) I believe the same as yours, and that was without a water rail fitted. Could you get yours on and off with the RF water rail fitted ? Mine was the geometry of the down pipes dropping between the block, bulkhead and the chassis rails when trying to feed it in from above. I dropped the cross member to increase the clearance to fit the manifold. It works but I hope I don’t have to go removing the manifold when it’s all done as it will be a right pain in the arse once all the front running gear is connected to the cross member.
    Plan for engine fitting is to lift it into place from underneath with the gearbox and exhaust manifold fitted. Engine is on my trolley now, sitting in the cross member with the gearbox fitted whilst I get on with other jobs in the engine bay whilst there’s plenty of room.
    Donnie said a similar thing about the crank breather, I looked at other options but figured Ford spent some time and money working out the best option so I stuck with it. I’ve removed the spring and ball stopper from the valve so it’s just venting and will plumb it into a catch can.
    More updates to follow
    Last edited by Zakspak; 22-07-2023 at 23:32.

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

    No - I could not fit the ex. mani with engine in bay and cyl. head / RL rail fitted! I had to lift the head off (with the RL rail obvs) then get the ex mani (same as yours) in the hole and hold it back out of the way whilst replacing the head. This is when I think I screwed up the cam timing so when I tried to start it . . . . . . it clattered / snapped two valves requiring a new head (cheaper than getting new valves + machinework!) Silly mistake but checked the timing multiple times with new head LOL!

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

    Quote Originally Posted by Zakspak View Post
    I checked the shoes and they are all the same, so swapping shoes around will give the same result.
    I'd be interested to see what you have fitted for a comparison. I'm going to look into this a bit more just in case there is a problem with the shoes I've got, although they came from Burtons and were in a sealed box, still worth checking.
    I marked the lining material on the shoes with some chalk on this photos of my Escorts left rear brake. Note how the shoes are actually the same, but the lining material is located in different positions.

    20230723_130111a.jpg

    20230723_130150a.jpg

    20230723_130208a.jpg
    Last edited by Willi; 24-07-2023 at 07:12.

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

    If I spot it right on a photo you previously posted it looks that your brake shoes are the same as mine.

    12345.jpg

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

    [QUOTE=Willi;3779749]If I spot it right on a photo you previously posted it looks that your brake shoes are the same as mine.

    Willi, thanks so much for taking the time to follow this up and post your pictures. Yes clearly the shoes are different, so I’ve put them on wrong. I’ll have to swap that around. I can see what I’ve done now matching the leading shoes one side and the trailing shoes the other not noticing the lining position.
    That’s a real “gotcha”.

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

    [QUOTE=Zakspak;3779934]
    Quote Originally Posted by Willi View Post
    If I spot it right on a photo you previously posted it looks that your brake shoes are the same as mine.

    Willi, thanks so much for taking the time to follow this up and post your pictures. Yes clearly the shoes are different, so I’ve put them on wrong. I’ll have to swap that around. I can see what I’ve done now matching the leading shoes one side and the trailing shoes the other not noticing the lining position.
    That’s a real “gotcha”.
    Zakpak, do you put spacers on the rear axle? Or leave original? My dad put rear spacers

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

    Tom you asked me this before!
    No I don’t need spacers, the wheels fit nicely in the arches 8” front, 9” rear
    I may use a thin spacer 2-3mm to ensure the wheel nuts/stud combination I’m using has a few extra threads to tighten against. But I don’t need them for wheel alignment.

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

    [QUOTE=Zakspak;3779934]
    Quote Originally Posted by Willi View Post
    If I spot it right on a photo you previously posted it looks that your brake shoes are the same as mine.

    Willi, thanks so much for taking the time to follow this up and post your pictures. Yes clearly the shoes are different, so I’ve put them on wrong. I’ll have to swap that around. I can see what I’ve done now matching the leading shoes one side and the trailing shoes the other not noticing the lining position.
    That’s a real “gotcha”.
    I am glad I could help.

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

    With the engine together, before fitting I've got a 10 micron pre injector filter. Not wanting to drill any holes in the wings I've had to come up with a fitting idea and going onto the cross member seemed to be best. The bracket is all bench made.

    IMG_6149.JPG

    IMG_6150.JPG

    IMG_6216.JPG

    With the filter bracket done, dry fitting to make up the hoses.

    Still catching up on the updates

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

    Time to get the engine off the stand with the cross member fitted, and down on to the skate to fit the gear box.
    Front of the car will be lifted and the engine slid in from underneath then lifted into place.

    IMG_6223.JPG

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

    Fitting Type 9 gear box to Zetech E Black Top
    Going to go through this in a bit of detail in case anyone is doing the same and isn't sure.

    Fitting the pinto clutch fork to the aluminium bell housing

    The pivot pin is stepped and simply taps in to the drilled hole. Just got to decide the correct side depending on Left or Right hand drive.

    IMG_6224.JPG
    Pivot pin with rubber anti rattle sleeve fitted


    Pinto clutch fork for RH drive
    IMG_6225.JPG

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

    Clutch spigot bearing.

    Rear face, with the slightly wider rim and stamping
    IMG_6226.JPG

    Forward face, thinner rim, no stamping
    IMG_6227.JPG


    Liberally greased, and gently tapped into the crank shaft so its flush.
    IMG_6228.JPG

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

    Don't forget the sandwich plate, aligned on the dowels.

    IMG_6230.JPG
    Down on the RH side there's a "jigsaw" type join on the plate, that needs to sit flush before fitting the bell housing/gearbox otherwise the plate flexes and twists.

    Lightened fly wheel on. A socket and bar on the front crank bolt stops the crank turning while torqueing the fly wheel bolts (Don't forget to fit the crank sensor bracket first)
    IMG_6232.JPG

    Spare input shaft used to align the pinto clutch. (I was given this by the guy who fitted the ATB)
    IMG_6237.JPG

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

    The bell housing to gear box bolts use spring washers that without a flat washer chew into the aluminium. I got some washers that dropped into the machined recess and drilled them out to fit the bolts.

    IMG_6238.JPG

    With the bell housing fitted to the gear box it's time to fit to the engine

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

    IMG_6240.JPG
    Thrust bearing fitted.

    IMG_6239.JPG

    This was a bit tricky on my own. I used blocks of wood and plastic spacers to align the gear box to the engine. When it's aligned correctly it more or less slips straight on. This took some time to achieve, a second pair of hands would have been helpful.

    IMG_6242.JPG
    Done

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

    Clutch cable bracket.

    IMG_6245.JPG
    I've replaced the hex bolt with a better looking cap head.

    Starter motor fitted.

    IMG_6244.JPG

    Gear box support. I had to file a slot on the front to allow clearance for a webbing on the gear box.
    I've also drilled 4 small holes in the bottom of the mount to allow any water that could get in there to drain out
    IMG_6246.JPG

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

    The rear breaks, I've removed and re fitted the shoes in the correct orientation as pointed out by Willi.

    IMG_6379.JPG


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

    Break pedal box back on the bench for fitting the break light switch and setting the pedals up.
    I stripped the switch and cleaned it, then cut down the threaded section and the switch plunger.

    IMG_6293.JPG

    IMG_6294.JPG
    The pedals have been cleaned and the little surface rust removed and freshen up with a coat of gloss black
    The white line is a datum for the neutral position

    Output pipes fitted using copper sealing washers before fitting
    IMG_6371.JPG

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

    Pedal box fitted

    IMG_6372.JPG

    Reservoir fixing plate and break line plates fitted along with Speedo cable with new grommet

    IMG_6374.JPG

    View up under the dash
    IMG_6373.JPG

    That's it for now. Up to date. Almost ready to fit the engine and gear box.

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

    Coming along nicely. Thanks for taking the time to post up pics and keeping us up to date with your progress.

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

    Had a few jobs to do on the back end. The poly bush pads that sit around the leaf spring I thought were in contact on the sides so not sitting flat. So I've taken out the lower one each side and cut 3mm off the side wall. Once refitted and tightened there's now a 1mm gap between them.

    IMG_6473.JPG

    Also cut 10mm off the U bolts so there's 3-5 threads out of the nuts.
    Removed the front spring hanger bolt, trimmed that down and torqued it up. I hadn't done it before as wasn't sure if I'd be refitting the skate.
    Finally going around putting paint on the end of bolts.

    I'm thinking about removing the spring pads completely, but for now they can stay. If I take them out there's a few things to consider, I'll have to insert another 1/2" lowering block to keep the ride height, and make up a saddle to locate the spring in the base plate. I've some other thoughts for this. That can all wait for another time.

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

    Battery cable.
    I'm using tinned Ocean Flex 35mm2 cable. Worked out on loading and volt drop plus contingency. It has hard wearing chemical resistant insulation, is corrosion resistant, and very flexible. This is run in a flexible conduit for extra protection (belt and braces).
    I'm running this through the chassis rail.
    The conduit is a close fit to the cable. It took me 4 hours to feed the 4m of cable through the conduit.

    IMG_6477.JPG

    Routing under the rear seat, through a floor bung. Plastic bung will be cut to take the cable and act like a grommet.

    IMG_6478.JPG

    Out through the front jack point, there'll be a grommet here. The jacking holes aren't needed as the standard jack doesn't work with the X-pack kit. I've always used a scissor jack, ( I never liked the Ford jack, X-pack or not)
    I reinforced the jacking points on the chassis rails when I was preparing them for fitting.

    IMG_6479.JPG

    This is a dry run for trimming. It'll be coming out to have the battery and starter motor terminals fitted.

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

    The big news today. Now sitting on rear wheels !

    IMG_6484.JPG

    Seeing it sat on some wheels is a big deal, I hadn't anticipated the grin factor it would give.
    Even the Mrs came to the garage to see.

    As per a previous post I'm going to lift the front, pivoting the car on the rear wheels, to make clearance to push the engine/gearbox in under the front before lifting it into place. That could be happening tomorrow, watch this space.

    Anyone following this thread will note these aren't the wheels for this car. These are for a Capri I've been looking for and still not found. I missed out on one during the first lock down. So they are spare for now and have good tyres.
    I believe these maybe the JPS Capri wheels from their part number.

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

    5 days later. The engine and gear box has been in and out 3 times.

    Day one, preparing and setting up.
    IMG_6486.JPG

    IMG_6487.JPG

    IMG_6488.JPG

    Lifting point through the ARB bracket fixing
    IMG_6490.JPG

    IMG_6489.JPG

    Front lifted and engine being pushed into place
    IMG_6493.JPG

    First lift was very cautious as I'm on my own. Removed the oil cap to save lifting any more. Looks like it will clear but it's an illusion.
    IMG_6494.JPG

    In the hole, and the front lowered back onto the axel stands
    IMG_6495.JPG

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

    Exhaust fitted, ready to lift the engine into place.

    IMG_6504.JPG
    The engine is offset to the right to allow the exhaust to clear the chassis rail.

    IMG_6505.JPG

    IMG_6506.JPG

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

    Problems.
    I got it wrong with the ECU temperature sensor position.
    IMG_6519.JPG
    This completely through off the alignment of the gearbox mount and crossmember

    Doesn't look much
    IMG_6517.JPG

    The other issue is the battery cable, its just too close to the exhaust if I stick with my original plan
    IMG_E6511.JPG

    Battery cable will exit out the other side of the chassis rail and loop under to the starter motor.

    The temperature sensor I decided to make a cut out for it in the flange, I've marked the cut on the flange
    IMG_6510.JPG

    The other option would be to re position it to the side of the water rail, but as the paint is now damaged on the flange the cut out seems like the best option.
    IMG_6508.JPG

    So engine out. Cut out made with a tank cutter, and a coat of zinc primer
    IMG_6525.JPG

    Paint and lacquer
    IMG_6534.JPG

    Ready for refitting.

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

    Fitting No2. The cut out didn't work. It was so close that the sensor still contacted the flange as it was being lifted in damaging the paint. Once it was in position its was ok but if it ever failed I'd have to drop the engine to replace it. That's no good.

    Out with the engine again. Time to re tap the water rail moving the sensor to the side.

    IMG_6545.JPG
    This isn't the best position, as the sensor needs to be spaced out because it's too long.
    Ideally I should have put both sensors in the underside
    I'll use an aluminium plug in the top hole.

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

    With the temp sensor moved, it's in.

    IMG_6552.JPG

    IMG_6554.JPG

    IMG_6553.JPG

    IMG_6555.JPG
    With taking it in and out, the engine mounts became uneven in the cross member and caused the whole lot to skew off to the left pushing the rear end of the gearbox to the right, so the mounts had to be Knocked back into position to allow the mount to line up.

    IMG_6556.JPG

    IMG_6557.JPG

    It's probably going to have to drop down again to do odd bits like loom installation, but I don't think I'll have to fully remove it, we'll see. I'll also check the 4* drive train line described when I did the dry fit, I've used temporary plain nuts which will be replaced with nylocks.
    Battery cable also moved to exit on the outside of the chassis rail and that seems to work ok, just need to think about the best and tidiest way to secure it, probably a couple of P-clips.

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

    Quote Originally Posted by Zakspak View Post
    With the temp sensor moved, it's in.

    Attachment 88660

    Attachment 88661

    Attachment 88662

    Attachment 88663
    With taking it in and out, the engine mounts became uneven in the cross member and caused the whole lot to skew off to the left pushing the rear end of the gearbox to the right, so the mounts had to be Knocked back into position to allow the mount to line up.

    Attachment 88664

    Attachment 88665

    It's probably going to have to drop down again to do odd bits like loom installation, but I don't think I'll have to fully remove it, we'll see. I'll also check the 4* drive train line described when I did the dry fit, I've used temporary plain nuts which will be replaced with nylocks.
    Battery cable also moved to exit on the outside of the chassis rail and that seems to work ok, just need to think about the best and tidiest way to secure it, probably a couple of P-clips.
    Hi friend, is there any progress on the renovation? I would be happy to chat with you about some questions in my email and I will send you the email address details

  39. #594
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Hi Tom, yes making progress but not had time to update and it’s little bits around the engine bay and loom adjustments which are time consuming and don’t show much progress. I’m hoping to update this week time and work allowing
    Please feel free to ask questions. There’s a wealth of knowledge and experience on this site. I’d suggest asking in the “Info request “ area unless it’s something specific to my build then ask here.. As per your previous request for email details I don’t have time to answer questions here and on email, and again there’s plenty of people here with more knowledge than me.
    Why don’t you post some pictures and info on your dad’s car ? So far all you’ve posted is one or 2 pics of its parked on a drive way.

  40. #595
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Quote Originally Posted by Zakspak View Post
    Hi Tom, yes making progress but not had time to update and it’s little bits around the engine bay and loom adjustments which are time consuming and don’t show much progress. I’m hoping to update this week time and work allowing
    Please feel free to ask questions. There’s a wealth of knowledge and experience on this site. I’d suggest asking in the “Info request “ area unless it’s something specific to my build then ask here.. As per your previous request for email details I don’t have time to answer questions here and on email, and again there’s plenty of people here with more knowledge than me.
    Why don’t you post some pictures and info on your dad’s car ? So far all you’ve posted is one or 2 pics of its parked on a drive way.
    Yes, I will talk to my father with a screen, I will upload photos from our project in about a week and a half, the car will be towed to the garage to build new pipes, and a few more things, the problem is that the photos are published around the web, I understand

  41. #596
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Quote Originally Posted by Zakspak View Post
    Hi Tom, yes making progress but not had time to update and it’s little bits around the engine bay and loom adjustments which are time consuming and don’t show much progress. I’m hoping to update this week time and work allowing
    Please feel free to ask questions. There’s a wealth of knowledge and experience on this site. I’d suggest asking in the “Info request “ area unless it’s something specific to my build then ask here.. As per your previous request for email details I don’t have time to answer questions here and on email, and again there’s plenty of people here with more knowledge than me.
    Why don’t you post some pictures and info on your dad’s car ? So far all you’ve posted is one or 2 pics of its parked on a drive way.
    And a question I wanted to ask you, did you install front suspensions, what shock absorbers did you install? And what shock absorbers did you use, are they custom or normal and what springs do you have? thanks tom

  42. #597
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Please have a look back through the thread, everything I've done and used is recorded here, if not I've not done it.
    GAZ inserts in RS struts, -2" fast road Coil springs, can't remember the loading, I bought them 30 years ago.

  43. #598
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    ECU temp sensor

    IMG_6706.JPG
    Dowty seal, DIY threaded spacer, Washer

    IMG_6707.JPG

    IMG_6708.JPG
    Fitted, and M12 plug fitted in the top hole

  44. #599
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Batter cable fixing to front chassis rail

    IMG_6723.JPG

    P-clips, chassis rail tapped to M5 and an M5 Rivnut used in the strengthener

  45. #600
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Final adjustments to the loom, placing loom supports (P-clips), Fitting relay sockets. All the holes get the usual zinc paint, primer then 2k paint for protection, all put on with a fine brush, I've used a mix of rivnuts and M5 screws and nylock nuts depending on access .

    IMG_6862.JPG

    IMG_6863.JPG

    IMG_6865.JPG

    IMG_6864.JPG

    Loom is now removed ready for wrapping.

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