User Tag List

+ Reply to Thread
Page 17 of 19 FirstFirst 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 LastLast
Results 641 to 680 of 724

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

  1. #641
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Fitted these 10mm to 15mm push fit radiator fittings to the heater matrix pipes.
    Iíve searched for the smallest and lightest fittings and as a bonus they come in this black option rather than chrome.
    IMG_7791.jpeg

    This has worked out better than planned as the fittings are accessible from the engine bay, I thought they would sit just inside the bulkhead meaning removal would have to be done from inside and with a second pair of hands outside
    Heater matrix modification and dry fit of some push on fittings that are a fair bit chunkier that the black ones fitted
    IMG_1561.jpeg
    IMG_1560.jpeg

  2. The Following 2 Users Say Thank You to Zakspak For This Useful Post:


  3. #642
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    [QUOTE=rallyrob;3787590]How have you modified the heater matrix then? Are those matrix outlets still set straight out of the bulkhead, or have you put a bend on them to pass the head?

    Hi Bob,
    Iíve attached some pics on the post above. They are straight via a 15/10 reducer. If you go back to Page 12 of the thread the whole heater strip, modification and rebuild is listed there including all the parts Iíve used. Let me know if you need anything else

  4. The Following User Says Thank You to Zakspak For This Useful Post:


  5. #643
    Mechanic JonSegger's Avatar
    My Race Car
    My 1st Project
    My 2nd Project
    Join Date
    Jan 2004
    Location
    Sunny Suffolk
    Age
    51
    Posts
    507
    Thanks
    11
    Thanked 18 Times in 17 Posts

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

    This is coming along great! Superb work

  6. The Following User Says Thank You to JonSegger For This Useful Post:


  7. #644
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Coolant plumbing.
    This has been the main focus for the last couple of weeks. As per the previous the piping set from Retro Ford isnít working for me, so Iíve had to work it all out myself. Quite a lot of measuring and making up templates.
    This is the main part of a £300+ order. . No top heater hose and a couple of 90* elbows missing. All the clamps are stainless and this also includes the parts for the engine breather

    IMG_7850.jpeg

    Heater top hose. This is an RS1600 BDA top hose which connects from the water rail take off. I trimmed the end that connects to the heater a little to sit more horizontal across the rocker cover

    IMG_7855.jpeg
    Iíve fitted compression olives to the push fit connectors as they are 15mm and the pipe is 16mm inner diameter. Thought Iíd taken a picture but I havenít.

  8. #645
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Thermostat housing fitted and wiring terminated with fan switch. Using a 91*C thermostat

    IMG_7856.jpeg

    The housing is from a Transit. The 8mm take off will be capped.

  9. #646
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Iím using an expansion tank. Iíve painted the back and the fixing wings just because keeping them clean in the future will be a pain

    IMG_7854.jpeg

  10. #647
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    The top and bottom hoses are both made up of 1x 135* & 1x 45* bends of 32mm pipe. The top one was easier to cut to size, I then used those 2 parts to check how the bottom hose would fit and work out where the cuts where needed.

    This is the bottom pipe put together with the 32x32x16mm T connector. 16mm take off for the expansion tank feeds.
    IMG_7857.jpeg

    The heater return hose has to connect into this bottom radiator hose, so Iím using this self sealing take off
    IMG_7859.jpeg

    IMG_7858.jpeg

    IMG_7862.jpeg

    Iím not 100% sure about the clamps. Theyíre much better than jubilee clamps but a lot bigger, although that does mean they donít cut into the pipe and tighten up very positively

  11. #648
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Top heater hose fitted. Iíve put some protection around the pipe where it could come into contact with the rocker cover. This is a strip of rubber from an inner tube stretched around and tapped using cloth loom tape

    IMG_7861.jpeg
    Water rail take off

    IMG_7860.jpeg
    Top heater pipe fitting

    Picture quality is a bit pants.

  12. #649
    Mechanic beeRS's Avatar

    My 1st Project
    Join Date
    Apr 2007
    Location
    Chelmsford
    Age
    52
    Posts
    773
    Thanks
    114
    Thanked 76 Times in 66 Posts

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

    Plumbing can be a pain (and expensive!). Looks like you’re getting there though .
    Strictly speaking, I think that you’ve got a header tank there - not an expansion tank. Are you planning on using an expansion tank too? you probably don’t need one.
    Those hose clamps look decent. Can I ask, what brand they are?

  13. #650
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Quote Originally Posted by beeRS View Post
    Plumbing can be a pain (and expensive!). Looks like you’re getting there though .
    Strictly speaking, I think that you’ve got a header tank there - not an expansion tank. Are you planning on using an expansion tank too? you probably don’t need one.
    Those hose clamps look decent. Can I ask, what brand they are?
    Thanks Beers, yes you’re right it’s a Header tank not expansion. No expansion tank. It’s got an 8mm feed in from the top of the Rad filler neck, then an 8mm overflow/vent from its neck to atmosphere.
    The clamps are really good quality and were recommended by quite a lot of people on various sites. They just seem very chunky but that is off set by the quality, pressure surface area and positivity of the screw tightening. A couple of places I’ve got to use something else because of space or clearance.
    They’re “T-bolt clamps” or sometimes called Mikalor clamps. My ones come via Auto Silicone hose UK, and aren’t branded. Mikalor are sold via various places, they’re the same thing but generally more expensive. They also come as stainless steel or nickel plated. I’ve gone with stainless.
    I’ll be doing more updates on this and how I’ve done the hole system, just waiting on some formed pipes to arrive, so I’ve come to a stop until after Christmas now but I’ve another little job to pick up on that I started planning way back in February to keep me making progress.

  14. The Following User Says Thank You to Zakspak For This Useful Post:


  15. #651
    Racer Decade Plus User

    Join Date
    May 2012
    Location
    Camberley, Surrey
    Posts
    3,248
    Thanks
    5
    Thanked 356 Times in 341 Posts

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

    The 'Mikalor style clamps' are superb with silicone hoses due to the rolled edges that won't bite in and cut the hose - I use them a lot, generally in SS, as on bikes, normal ones suffer A LOT with salt! @Zakspak - have you drilled a bypass hole in your thermostat? Otherwise you'll get virtually no flow in the heater circuit till it opens!

  16. #652
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Quote Originally Posted by katana View Post
    The 'Mikalor style clamps' are superb with silicone hoses due to the rolled edges that won't bite in and cut the hose - I use them a lot, generally in SS, as on bikes, normal ones suffer A LOT with salt! @Zakspak - have you drilled a bypass hole in your thermostat? Otherwise you'll get virtually no flow in the heater circuit till it opens!
    Totally agree Katana, it’s just a shame they can’t make them a little more streamlined. I ordered some that looked less chunky but turned up just that same.
    One point that’s really important is sizing for anyone thinking of using T bolt clamps. They have a very limited range just a few mm. The advice was get clamps with the range that is +&- the pipe outer diameter size, that’s a bit obvious but the ones I got for the 16mm pipes had a range 23-25mm don’t work in a couple of places because the wall thickness of the pipe is slightly thicker. I’d recommend getting the pipes, fitting them then measuring the pipe diameter and ordering clamps as required.

    Re the thermostat, it comes with the hole drilled and a brass widget (pin through the hole) that prevents it getting blocked.

  17. #653
    Spanner Monkey

    Join Date
    Oct 2001
    Location
    Shropshire
    Age
    51
    Posts
    243
    Thanks
    18
    Thanked 23 Times in 19 Posts

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

    Great work Zakspak.

    Re silicon hose clamps i have always used the stainless steel ABA ones, they have a band on the inside. I have used them on all my builds since 1996, they are expensive and only available from Demon Tweeks but worth it. They do a cheaper steel version but comes with the blue worm gear and i dont like the look of them.

    https://www.demon-tweeks.com/uk/aba-...e-clip-247448/

  18. #654
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    [QUOTE=prox;3788359]Great work Zakspak.

    Re silicon hose clamps i have always used the stainless steel ABA ones, they have a band on the inside. I have used them on all my builds since 1996, they are expensive and only available from Demon Tweeks but worth it. They do a cheaper steel version but comes with the blue worm gear and i dont like the look of them.

    Thanks Prox,
    See what you mean with those ABA clamps, they’re very neat, quite a price tag though and I’ve already committed to the T-bolt clamps. Good to know about options

  19. #655
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Clutch cable fitted.
    I tried a 100cm RS2000 cable which looped around the front of the engine mount, but it made the fitting at the bulkhead sit at an awkward angle. This is the 76cm Kent engine cable and it sits perfectly.
    IMG_7945.jpeg

  20. #656
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    More work on the cooling hoses.
    Radiator top hose
    IMG_7942.jpeg

    Front heater return hose from Modine oil cooler
    P-clips to secure it on the anti dive bar with nylon spacers to align the pipe with the self sealing takeoff in the radiator bottom hose
    IMG_7941.jpeg

    Iíve used slightly different hose clamps on the 16mm pipes, stainless and less chunky with a similar slide over clamp band and positive tightening.
    IMG_7943.jpeg

    IMG_7944.jpeg

    IMG_7947.jpeg

    IMG_7948.jpeg

    Just waiting on a restock of a 300x300 16mm 90* elbow so I can finish off heater outlet to Modine inlet.
    Few jobs are being held up waiting for bits a pieces.
    Going to look at fitting front legs, steering rack and column while I wait for the hose and bits, just want to give myself as much space as possible while making up cooling hoses.

  21. #657
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Nothing major for the first update of the new year.
    Donít want any empty bolt holes as rust traps

    Rear chassis exhaust mount fixings
    IMG_7956.jpeg

    Rear anti-roll bar chassis mounts. Simple plastic plugs.
    IMG_7953.jpeg

    IMG_7954.jpeg

    Spayed protective light grease, just belt and braces, into the tubes before fitting the plugs. These have fitted better than I thought
    IMG_7955.jpeg

  22. #658
    Mechanic beeRS's Avatar

    My 1st Project
    Join Date
    Apr 2007
    Location
    Chelmsford
    Age
    52
    Posts
    773
    Thanks
    114
    Thanked 76 Times in 66 Posts

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

    This is coming along nicely. The plumbing job looks neatly done. Where did you get the little plastic bung for the chassis hole? I need some for a similar job.

  23. #659
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Quote Originally Posted by beeRS View Post
    This is coming along nicely. The plumbing job looks neatly done. Where did you get the little plastic bung for the chassis hole? I need some for a similar job.
    Thanks beeRS. I’m happy with the plumbing so far. Bit frustrating waiting for the last pipe to be back in stock, but been told it should now be next week. Currently working on a solid state voltage regulator for the dash. Initial test done last night, belt and braces tests today and when it’s all together I’ll post up here

    https://www.ebay.co.uk/itm/401672855599
    Plastic end plugs, if that link doesn’t work let me know and I’ll try again

  24. The Following User Says Thank You to Zakspak For This Useful Post:


  25. #660
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Instrument gauge voltage regulator
    This has been a project Iíve had planned for some time and just now got on to putting it together.
    Back ground to this :- the analog regulator doesnít give the most stable voltage output and much worse can fail to short circuit allowing full battery voltage onto the temperature and fuel gauge resulting in a puff of smoke and burnt out gauges.
    The solid state voltage gauge isnít a new thing, Ford went over to them on the late Mk3 Capri instruments and probably other similar aged models.
    All Iím doing is removing the analog internals and replacing them with a solid state (electronic) regulator.
    This is a really simple mod.
    Iím using a regulator from a standard Escort dash, (with or without rev counter) and fitting it to an RS2000 dash. This means the fixing bracket has to be moved. This kills 2 birds, one stone :- reliable voltage and availability. The RS regulator being extremely difficult to find so if you need one of those this will solve that problem.

    Basic circuit. Disregard the 2 capacitors on the 5v regulated output. (Iíve lifted this diagram just for illustration)
    image3.jpeg

    Standard Escort dash regulator
    image0.jpeg

    7805 Electronic regulator pin diagram (The 7805 is a standard component very available)
    image1.jpeg
    Note the fixing lug is also ďGround, -ve ď. Iím using the ground pin to be sure of a good return path.

    Regulator stripped down.
    IMG_8004.jpeg

    Iíve marked the input and output terminal's on the inside of the paxalin base. On the underside next to the contact that pushes into the dash the 12v input is marked ďIGNĒ, a little clean with a cotton bud will make it visible and remove any doubt to what goes where.
    The electronic voltage regulator, capacitor, 3 pin plug and fly lead wires. The analog parts now removed
    IMG_8006.jpeg
    Hole in the cover is where Iíve removed the fixing bracket. This was simply twisted to brake the small spot weld, this need to be done slowly so as not to rip the metal off the cover.

    Components fitted.
    IMG_8007.jpeg
    Keeping with standard escort wire colours
    Yellow/Black - Ignition On 12v input
    Red - 5v output
    Brown- input / output ground, -ve
    Note the small tab on the paxalin base is the ground,-ve tab and makes contact via the cover and through the fixing bracket to the instrument ground,-ve wire, so this all needs to be clean and make good contact.
    The capacitor has a white strip and ď-ď symbol to mark the -ve pin which is soldered to the ground tab.

    Regulator cover cleaned up from any surface rust and fixing bracket riveted on. Wires cut ready to fit the plug.
    IMG_8028.jpeg
    Heat shrink on the regulator pins.

    Put back together and fitted to the back of the dash. You canít see it but thereís heat shrink around the fly leads where they come through the casing to protect against chafing.
    IMG_8178.jpeg

    Prior to fitting I tested this on a 12v power supply, a very simple power supply with output range from 12-18v and my output voltage (5v) was nice and stable, just whatís needed.
    The plug in the dash is one Iíve made up for testing.

    Testing the gauges from the battery
    IMG_8176.jpeg
    All good
    IMG_8177.jpeg

    Hereís the reason for the fly leads and plug
    IMG_8183.jpeg
    The electronic regulator needs to dissipate the heat it generates so a M3 rivnut in the steering column support bracket for fixing it and that bracket will soak up more than enough heat. The plug allows easy fitting and removal of the dash.

    Some reasons around how Iíve done this.
    The input capacitor soaks up voltage spikes giving a smooth input from the variable voltage from the battery/alternator. This is a 100v 33 micro farad capacitor. The 100v means itís very reliable for this purpose.
    Output capacitors not required because the output voltage is stable.
    Using the support bracket as a heat sink is because there is potential for 90*C +, (max not normal) being produced by the regulator in this set up and Iíd need a fairly large heat sink stuck on the back of the dash, which isnít practical. I had planned to use the regulator casing but itís no way big enough and I donít want any unnecessary heat messing up the plastic or PCB of the dash.
    The heat generated is a product of the load on the gauges and input/output voltage. Gauges with a lower loading will produce less heat but all the gauges Iíve checked are the same (Escort gauges). If youíre looking at this for another car youíll have to do the calculations.
    Save people telling me that theyíve seen a different set up, there will be depending on makes and models.
    This is version one and Iíll be changing a couple of things on the next one that will be used in the car. Longer fly leads, and the yellow/black wire comes from a different supplier than I normally use and isnít as good quality.

  26. #661
    Racer Decade Plus User

    Join Date
    May 2012
    Location
    Camberley, Surrey
    Posts
    3,248
    Thanks
    5
    Thanked 356 Times in 341 Posts

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

    I heard from someone a lot better at electronics than me, that the Ford gauges (or maybe the RS ones in particular?) use 7 or 8v supplies. There used to be a 7808 regulator which was ideal but no longer available!
    Obviously with a 'bimetal strip' gauge, voltage is everything so under or over volts will give misreading! I can't prove or disprove any of this - just what I've heard.

  27. #662
    Pole Position Decade Plus User
    Turbosport Administrator
    Miniliteman's Avatar

    Join Date
    Feb 2004
    Location
    the Netherlands
    Posts
    4,904
    Thanks
    38
    Thanked 614 Times in 561 Posts

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


  28. The Following User Says Thank You to Miniliteman For This Useful Post:


  29. #663
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Quote Originally Posted by katana View Post
    I heard from someone a lot better at electronics than me, that the Ford gauges (or maybe the RS ones in particular?) use 7 or 8v supplies. There used to be a 7808 regulator which was ideal but no longer available!
    Obviously with a 'bimetal strip' gauge, voltage is everything so under or over volts will give misreading! I can't prove or disprove any of this - just what I've heard.
    The gauges use 5v, both standard and RS Escorts, Mk2. I’ve not checked a Mk1 dash. I may do in the future as I’ve got one tucked away. Different cars different supply voltage, resistance and load so always check.
    As far as accuracy goes it’s not just the regulator supply but also the sensor as this uses resistance to control the needle on the gauge. I described further back in this build thread cleaning and servicing the fuel tank sender (sender is a bit confusing as it’s actually at the end of the circuit as is the temperature sensor) A poor sender will have as much, possibly more impact on the gauge reading as they are prone to higher resistance with age and it’s this high resistance that gives the empty tank reading. From memory the tank sensor was around 80 ohms at empty after servicing (don’t quote me I’ve not looked back), effectively preventing any electrical flow through the gauge and the zero reading.

    As I mentioned in my post, the later Capri was fitted with an electronic regulator. I’ve got one of those stashed away, so I’ll dig it out at some point and see what Ford used then and I’ll check gauge voltage/ resistance as a comparison just for interest.

    Also in my post the pic of the standard regulator, there’s a component to. It’s a capacitor on the output side. This is to absorb voltage spikes which are likely with an analog regulator. Not all standard dashes had this capacitor.

  30. #664
    Pole Position Decade Plus User
    Turbosport Administrator
    Miniliteman's Avatar

    Join Date
    Feb 2004
    Location
    the Netherlands
    Posts
    4,904
    Thanks
    38
    Thanked 614 Times in 561 Posts

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

    My 2 cents: I measured several OEM regulators (both new and used, both RS and std) and I found that the average voltage to the gauges wasn't 5V but 5.5 - 5.6 Volts. When I fitted a resistor as a dummy tempsensor so that the tempgauge would go to exactly full-scale with a 5V supply instead of the regulator the gauge would go to between 3/4 and full. With 5.6 Volts it would go to exactly full scale. So the solid-state regulator I made years ago gave that output voltage.

    About you design: the 7805 gives a stable output voltage even without an output capacitor but only if the spikes on the input and output (EMC) are within reason. My design had both input and output capacitors and not elco's but special automotive solid alcaps. The elco is a very slow acting capacitor, a high and short voltage spike just goes straight through to the regulator, especially if it's mounted far away from the regulator. The long wires soldered to the regulator don't help either.
    The 7805 can deliver 1 Amp max and can dissipate 2 Watt max if cooled. When both gauges are at full scale these limits are exceeded. And the 7805 will shut down.
    Also I would add a series diode to protect against wrong connections / reverse voltage.

    The modern-ish solid state version that Ford sold in the 80's also has a 7805 regulator; I tried that also and the gauges don't go to full scale also when they should.
    You can buy an electronic version of the regulator via ebay which uses a switched output so it doesn't get hot. But that also gives 5 Volt and comes with 3 wires which you have to connect yourselves to the right connections at the back of the dash. I made a modified version of such an electronic regulator which gives a 5.5 Volt output. Sold a batch of these to someone on the Old Skool Ford forum and he sells them to members.

  31. The Following User Says Thank You to Miniliteman For This Useful Post:


  32. #665
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Fuel pump electrical connections
    Iíve been trying to find some rubber terminal covers for the fuel pump for months with no luck, but while making up some test leads for the gauge regulator I thought the ďcrocodile clipsĒ covers might do the job, and they do, so fuel pump is now connected
    Plenty of electrical grease on the terminals to keep out damp.

    IMG_8014.jpeg

    IMG_8016.jpeg

    IMG_8017.jpeg

    A wrap of rubber inner tube held in place with a cable tie to keep damp out of the fuel joint.
    IMG_8018.jpeg

  33. #666
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Back inside, fuel pressure pipe terminated and cable wrap fitted to stop it rattling, scratching paint or wearing wiring and marked with yellow tape to make it easy to see from underneath the dash

    IMG_8019.jpeg

    Plugs fitted. Iím having problems with the speedo cable. This fitting is different from the original so got to deal with this, maybe even put the original speedo cable back in ??? Back to this later.
    IMG_8184.jpeg

    Been about 30 years since I had a dash in the car. Where did those years go. This is a spare dash for testing, I have the early white needle dash that came out in 1993/94 when I took it off the road and described refurbishing sometime back in this build thread.
    IMG_8185.jpeg

    Had to revisit the oil pressure pipe as the straight fitting meant a kink in the pipe going around the steering column bracing bracket which of course is directly behind the oil pressure gauge. A 45* fitting and shortening the pipe by 8cm has given a much better fit.
    IMG_8248.jpeg
    Can just make out the kink in the pipe behind the straight fitting

  34. #667
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Adjustable track control arms. (TCA)
    What a pain in the arse !
    Hours spent messing about getting the poly bushes fitted. Everywhere else the poly bushes have been quite straight forward to fit. These are 3mm wider than the original rubber ones and were a single piece. So I cut them in half but couldnít get them in. Ordered another set which come in 2 parts. Same problem. Phone call to the TCA manufacturer, advised to warm them up in boiling water. That worked but they wouldnít stay in place, once I took the pressure off them they popped out. Stopped using the silicone grease but still they wouldnít stay in place. On top of that because they are now compressed I couldnít get the steel sleeves in.
    Eventually after too many frustrating hours on this job I got it done using the original set of poly bushes that I cut. I canít give a detailed description as each side was done slightly differently. I used a combination on a bench vice, nuts and bolts with penny washers heating the bushes up and clamping them together to stop them coming apart
    IMG_8025.jpeg

    IMG_8075.jpeg
    Original rubber bush as comparison

    I then adjusted the TCAs to approximately the same length as the original
    IMG_8074.jpeg

  35. #668
    Bodger

    Join Date
    Sep 2023
    Location
    Suffolk
    Age
    54
    Posts
    52
    Thanks
    14
    Thanked 13 Times in 12 Posts

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

    Quote Originally Posted by Zakspak View Post
    I saw that picture and thought, croc clip insulators, thats a great idea, I bought a box of 200 croc clips in Lidl the other day, you can never have enough, but it does mean I have spare covers

  36. #669
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    TCAs, steering rack and ARB fitted
    Fortunately the TCAs were fairly simple to fit to the crossmember just requiring tapping into place, although more messing about required when I realised the adjustment section was not equal on both sides so re positioned to the centre.

    IMG_8077.jpeg

    IMG_8076.jpeg

    ARB was a bit of a pain to. The TCA end bushes deforming as I tightened the end nuts up ( no not fully tight I know that is done weight on wheels). Got it sorted by adjusting the TCA outwards then slowly tightening the nuts making sure the bushes and washers were all square.
    IMG_8165.jpeg

    Then despite the anti dive bar being bolted up to the chassis brackets no problem at all, once the ARB was on one bolt was out of line and I had to use a G clamp to apply pressure between the end of the anti dive bar and the chassis bracket to get it back in line.
    IMG_8166.jpeg
    Anyway all done, just a lot more time that expected.

  37. #670
    Pole Position Decade Plus User
    Turbosport Administrator
    Miniliteman's Avatar

    Join Date
    Feb 2004
    Location
    the Netherlands
    Posts
    4,904
    Thanks
    38
    Thanked 614 Times in 561 Posts

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

    Quote Originally Posted by Zakspak View Post
    Adjustable track control arms. (TCA)
    What a pain in the arse !
    Why do you use poly bushes?

  38. #671
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Quote Originally Posted by GrahamU View Post
    I saw that picture and thought, croc clip insulators, thats a great idea, I bought a box of 200 croc clips in Lidl the other day, you can never have enough, but it does mean I have spare covers
    Thanks Graham, might try our Lidl to see if they have any, save ordering them

  39. #672
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Quote Originally Posted by Miniliteman View Post
    Why do you use poly bushes?
    That’s a loaded question ! Why not ?
    I’m using the super flex bushes, so more durable than modern rubber and generally easier for me to fit at home in my garage and not as firm as the other poly bush types so more suitable for a mainly road car, side benefit being black they don’t show out.

  40. #673
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Finally sorted the last part of the coolant plumbing. Fortunately the £30 long leg 90* elbow remained out of stock so I tried the remaining length of straight/flexible hose I had left and found it works perfectly and the elbow wouldnít have. Win win

    Steering column also fitted. Bracket made up to secure the coolant hose between the oil cooler and the heater matrix
    IMG_8210.jpeg

    IMG_8231.jpeg
    Wrapped the coolant pipe with cable sheathing as added protection as it passes the X-member

    Another bracket made up to support the speedo cable keeping it clear of the steering column union
    IMG_8211.jpeg
    Itís running close to the union, so the bracket is insurance like the one for the hose.
    IMG_8230.jpeg
    IMG_8229.jpeg

    The steering column bulkhead grommet was an original Ford and looked in good order but felt a bit hard, and sure enough it split in a couple of places whilst fitting the column, so unfortunately itís had to be replaced with a new reproduction one.
    The replacement came from Historic Racing and is very good quality. Iíve had a couple of bits from them and not been disappointed
    IMG_8247.jpeg

    Had a successful day today but got too late for pictures so more to follow soon.

  41. #674
    Bodger

    Join Date
    Aug 2012
    Location
    Scotland
    Posts
    128
    Thanks
    29
    Thanked 18 Times in 17 Posts

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

    Iíve decided to stick with the 6 dial clocks in my mk1 rather than going back to a twin dial set up. Current dash has Smith gauges fitted and although look ok and are far brighter than the original ones, they arenít very accurate. Ended up buying Racetech rev counter and speedometer with gps so going to bin the wheel speed sensor etc and try something different. On the lookout for a spare set of clocks atm

    Again, loving the attention to detail. Superb

  42. #675
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Quote Originally Posted by FrankC View Post
    I’ve decided to stick with the 6 dial clocks in my mk1 rather than going back to a twin dial set up. Current dash has Smith gauges fitted and although look ok and are far brighter than the original ones, they aren’t very accurate. Ended up buying Racetech rev counter and speedometer with gps so going to bin the wheel speed sensor etc and try something different. On the lookout for a spare set of clocks atm

    Again, loving the attention to detail. Superb
    Thanks Frank, makes posting worthwhile to hear people find it interesting. Your project sounds interesting. If you have time post some pics up of what you’re doing always good to see options

  43. #676
    Bodger

    Join Date
    Aug 2012
    Location
    Scotland
    Posts
    128
    Thanks
    29
    Thanked 18 Times in 17 Posts

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

    I donít have a garage at the house sadly but do have a lock up not far away. No electricity either so car has been tucked away over the winter and any work has been on put hold in the meantime. I do plan to take some pics when the better weather comes but will be more of a before and after kinda thing rather a work in progress.

    2A6D756A-B646-4E91-A3E2-C61D64B1AF4E.jpeg

    On a tight budget but have been buying a few bits here and there when funds allow.
    Mainly, New twin cam arb with std position double width brackets
    Quarter bumpers
    New dials
    Centre console
    5 speed box (still to get long 1st gear kit fitted)

    Still to buy: a set of Minilite style wheels once I nail down sizes
    RS turbo front seats thatíll I get upholstered to match rear (have new contour seats but want recliners)
    Once the interior and exterior is sorted Iíll save the pennies and tidy up the engine bay. Hopefully with the addition of a ported head and mild cam and keep the 32/36 carb

  44. #677
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Nice car Frank, great colour. Look forward to see more of it in the future
    How I wish I could have held on to my Mk1

  45. The Following User Says Thank You to Zakspak For This Useful Post:


  46. #678
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Another bracket, this one is to support the speedo cable and is fitted at the gearbox support. Just shortens the distance between the last clip and the gearbox input so thereís less chance of it drooping.
    IMG_8269.jpeg
    The hole is to allow a cable tie for positive fixing of the cable

  47. #679
    Mechanic

    My 1st Project
    Join Date
    Apr 2017
    Location
    Essex
    Age
    53
    Posts
    801
    Thanks
    102
    Thanked 116 Times in 102 Posts

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

    Big news this weekend is getting the front struts fitted. She could be back on four wheels sometime soon, the first time since this project started in 2017 and Iím really happy with how they look.

    IMG_8266.jpeg

    After the difficulties with the other parts of the front running gear, I was hoping this would be fairly straightforward, and it provided to be. Had to think this through as the legs arenít light and lifting then holding them in position whilst getting the top mount bolts in without dropping them or damaging any paint is tricky on my own. Having got them secured at the top I used a bottle jack and a small piece of wood under the steering arm to compress the leg half the distance required to get the TCA in, then with the ARB and a leaver bar wrapped in some cloth to prevent any paint damage, with the bar braced under the cross member I levered the ARB down taking the TCA with it and once clear of the locating hole in the strut pushed the strut back to line the TCA up, before slowly releasing the ARB followed by the bottle jack. Boom done

    IMG_8267.jpeg

    IMG_8265.jpeg

    Steering arms connected, hard brake pipes fitted and flexible pipes connected.
    IMG_8270.jpeg

    Engine bay overview. Nice to have those strut top mount holes finally filled.
    IMG_8271.jpeg

    IMG_8268.jpeg
    Also fitted the oil catch can after dealing with a little paint blemish by the bonnet stay. This just needed a gentle rub down with 1500 wet and dry and then various polishing compounds on a dremmel polishing wheel. Of course thereís always a worry dealing with a little blemish, it could turn into something more difficult but not this time.
    Today I,ve fitted front brake pads and in the dash the RH window vent, canít remember why I had to leave it out, possibly because I hadnít fitted the wiper mechanism. Got a bit distracted having a tidy up that lead to stripping down and cleaning a spare RS2000 brake master and servo.

  48. #680
    Bodger

    Join Date
    Aug 2012
    Location
    Scotland
    Posts
    128
    Thanks
    29
    Thanked 18 Times in 17 Posts

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

    Love the clean look of the black against the white throughout the car. Right up my street. Interior going to be all black too?
    Think Iíll order a set of Samco classic black hoses for my car to get rid of the shiny blue ones fitted atm.

+ Reply to Thread

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts