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

  1. #281
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks GUL659W for looking in and the compliment. The loom is going to come through the original access in the bulkhead, but will be routed so as to be below the exhaust, and it will be heat shielded. The ECU set is designed to have an additional access through the bulkhead next to the original but that would be right over the exhaust, as well as an additional 50mm hole, (which I is excessive). So I’m going to combine the ECU loom into the original.
    Are you working on a similar set up or are you up and running ?

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

    Lovely work, been watching this closely as im doing a zetec mk1. using retroford engine mounts, i found the gearstick hole postion by measurement as my car was miles away from my garage getting the fab work done, i couldnt mount the engine so took some measurements and sent them to my welder .....good to see that my riser and stick hole seems to be in the exact postion to yours, using the seat mount box section as a ref point,.

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

    Thanks Erik, glad some of 5he pics have been of interest. How long until you think you’ll get your shell back ?
    I must get on and do an update here.

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

    Its sitting in primer at the moment, all the repairs are done, underside blasted etc, will be seeing some colour in the enxt couple of weeks, im just in the process of ordering everything i need to get it rolling, have also been planning what loom to use, ive been in touch with the guys at ST Motorsport who are going to build me a custom loom, switch panel and dash, i'll send them my Omex loom so they can match to that, the only std Mk1 escort electrical part im using is the indicator stalk, and wiper motor, so everything will be custom - and modern!

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

    Sounds good Erik, any pics of your car ?

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

    Been a while so update time.
    Just before heading off for a couple of weeks in Feb I did a check fit of my seat runners to the seats and sat one in the shell to make sure it all worked as the seats were booked in for re-trimming.
    IMG_7357.JPG
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    Might use these side trims that came on the seats as they make the seats look a bit more smooth, hiding the brackets.
    IMG_7363.JPG

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

    Quote Originally Posted by Zakspak View Post
    Thanks GUL659W for looking in and the compliment. The loom is going to come through the original access in the bulkhead, but will be routed so as to be below the exhaust, and it will be heat shielded. The ECU set is designed to have an additional access through the bulkhead next to the original but that would be right over the exhaust, as well as an additional 50mm hole, (which I is excessive). So I’m going to combine the ECU loom into the original.
    Are you working on a similar set up or are you up and running ?
    i previously had a silver top zetec in the car and running well - 175bhp on jenveys and emerald ecu. That went bang on a track day and instead of just dropping another in I decided it needed more power. And about 10 yrs ago I bought an st170 lump before anyone else was really doing them. Then decided it needed suspension mods at the rear to get the power down. It was 5 linked by a well known business up north and they did a crap job. I’ve since redone most of it again but tbh I’ve lost interest for many years after it was messed up by them and ended up building different tack/rally cars. I’ve now got my escort mojo back.

    With the emerald setup I had a separate loom going through another hole next to the original loom hole in the bulkhead but like you I’m going to link into one loom and use the original bulkhead edit point. An excuse for some gold headshielding in the engine bay....
    Last edited by GUL695W; 22-04-2020 at 22:18.

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

    Seat lined up ok in the car to. Like the engine, 26 years since I last had a front seat in the car, so couldn't resist a little sit in. Was higher than I remember, but felt good.

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

    Quote Originally Posted by GUL695W View Post
    tbh I’ve lost interest for many years after it was messed up by them and ended up building different tack/rally cars. I’ve now git my escort mojo back.

    With the emerald setup I had a separate loom going through another hole next to the original loom hole in the bulkhead but like you I’m going to link into one loom and use the original bulkhead edit point. An excuse for some gold headshielding in the engine bay....
    We crossed as I was updating, like busses, nothing then 3 come at once. Good job you didn't sell your escort after that agro. Can understand you loosing interest. It's difficult when someone mucks up your hard work when they should know better and even worse when you're paying them. Back in the day when rolling roads (Dynos) were far from common, I took my car to one having built a new engine with vernier timing and optical ignition and wanted it all set up properly. These twats stuck a very large cooling fan across my battery with less than ideal clamps without considering it's load. I wasn't aware of this and watching from outside, I noticed the indicators do some flickering, then smoke from the engine bay, followed by flames as the loom overheated, melted and caught fire. They just stood there open mouthed, no fire extinguisher in the bay. I was just grabbing one out of my boot when someone came in with one from the office and put the fire out. They then went on to charge me for the work even trying to add the cost of the extinguisher. Fortunately no major damage, but the car was off the road for a couple of months whilst I fixed it. However, silver lining, I took the opportunity to re work the engine bay and re paint the car in the White and blue colours along with other improvements.

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

    Back on the car, I've refitted the front scuttle using stainless steal rivnuts and dome head screws.
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Seats went off for re trimming.
    Before :-
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    Original back seat
    IMG_7649.JPG
    IMG_7650.JPG

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


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

    Also collected the re-finished dash top and boot spoiler. Both of which I thought were probably past it, especially the boot spoiler.
    But no, the guy has done a cracking job repairing the hole and crack in the dash top, and re surfacing the spoiler.
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    I've been busy on the front end. It's taken far longer than I thought. I had it in my head the front end would more or less just bolt back on. However, there's always room for improvement. So many hours have been spent, re working and modifying the wings and nose cone for a better fit and like the rear arches to reduce any stress on them. It's involved a lot of fibre glass work, which probably isn't very interesting to others. In one way working with fibre glass may seem like an easy option vs metal, but its not at all. It needs loads of prep time, with a lot of thought, cutting out the glass, planning laying it on as once it's gone off there's no adjustment, it can also be a messy job. In the warmer temperatures we have now the resin goes off a lot quicker to, nearly 3 times as fast as back in Feb. I'm glad I got the rear arches done while it was cold (that was always planned to be a winter job)
    I've added nylon screw inserts in place of steel ones that rust, re worked the back of the wings where they attach to the A post and the front mating faces of the wings and nose cone, removed and repaired the light boxes, re-worked the front arches for a nicer, smoother line. Made adjustments to the metal inner bumper, Extended the spoiler ducts and I'm working on forming an air box behind the grill, which will be opened up later, to channel air onto the radiator more efficiently.
    Taken the shell off the spit to and it's down on the skate.

    IMG_7237.JPG
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    Rear section being reworked. Lots of cleaning of old underseal before anything else
    IMG_7790.JPG

    Surface stress cracks need sorting out
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    Lower air intake sealed, to be re-cut later in a more clean, squire fashion
    IMG_7788.JPG

    Wing positioning initial fitting. I thought it was all good from when I originally fitted all this, but looking back at some old pics, it wasn't as good a I remembered.
    IMG_7889.JPG

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

    So after a lot of mucking about with resin and glass, putting wings on, then taking them off, head scratching, measuring, swearing, wondering how it could be that the wings had shrunk and the bonnet stretched. I had one of those moments of clarity where the obscure problem suddenly showed it's self. I've finally got it all to fit fairly smoothly together. There's still a fair bit of work to do refining the gaps, and repairing some knocks and scratches. But it looks like a car again, well not as I write this because it's all off again for those continued refinements.

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

    Quote Originally Posted by Zakspak View Post
    Sounds good Erik, any pics of your car ?
    Yeah i have a post under here

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

    Quote Originally Posted by Zakspak View Post
    Sounds good Erik, any pics of your car ?
    http://www.turbosport.co.uk/showthre...1541698&page=2

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

    Extending the bib spoiler ducts back to the valance. I'll open up slots in the valance and there will be a mesh screen fitted. Doesn't really need it as i'm not running big power, but it will add to break cooling, and allow a better air flow rather than it getting trapped in the ducts. I've shaped the ducts with a slight narrowing half way down that I hope will cause a small low pressure area that will help accelerate the air through All a bit of a nonsense, but may make a difference.

    IMG_7898.JPG

    Duct moulds
    IMG_7899.JPG

    IMG_7897.JPG

    This has worked out really well, I'll post pics next time (this was done last week. Back to tinkering, like getting the indicators fitting nicely etc etc

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

    Impressive, couldn’t respond to your thread as i have been overseas since the end of January and just back yesterday. Car is looking, great job on the seats and flip in heck the fella did a good job of resurfacing the spoiler

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

    Unbelievably its been nearly 4 months since the last update. I'd have said it should be done and in the paint shop by now, I wish. Sorting out the front end just seems like a never ending job. My own fault, I keep thinking of things I can tweak and improve, but better now than going back to it once it's done, or wishing I had.
    Again lots of fibreglass work which I've not pictured as I don't think its very interesting to look at, so there's been a lot more work done than it may seam.

    I've opened up the grill. Some thing I've had in mind since 1993 as cooling was always a problem even with an electric fan and big rad. Sounds easy, but I wanted it to look right. Seen lots of these grills opened but never one that was to my liking.
    Before I started marking and cutting I strengthened the grills from behind by building them up with glass, then flatting it all off as i'll be fitting a 6mm stretch steel mesh. This will give protection, strength to the grill and once painted black give a bit of the original look back.
    Marking this up was a right bugger due the the compound curve. This took 2 and bit long full days to complete and I've gone back to it a couple of times with the mini files to make adjustments.
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Then another problem that I wanted to sort from day one. The inner wall of the wing cut in rather than a nice 90* angle. I've come up with all sorts of ideas to do this but my final solution was make a filler piece and glass over the top, then remove the wing and grind the original wall away and remove the filler to leave a nice 90* wall.
    This isn't just aesthetic, the way it was I couldn't fit the bonnet side support rubbers.

    IMG_8029.JPG

    The filler to be glassed over.
    IMG_8030.JPG

    I've not taken a pic of the finished job so I'll do that another time, but it all worked out well

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

    Another modification. Extend and shape the front arch lower forward section. This will also lead in to a mod to extend the spoilers lower lip.

    IMG_8089.JPG

    Mould made up
    IMG_8102.JPG

    IMG_8103.JPG
    Needs another layer of glass, cleaning up and shaping, but before that I reworked the spoiler the wing fitting flange as part of the "make it all fit together better" plan Same both sides of course.

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

    Side skirts, had these bonded on before, but want them bolt on. Reason being bonding them on is a bit of a bodge and the paint cracks across the bonding. I've re visited these no end of times. This is after cleaning them up, initial alignment then preparing them for some glass work

    IMG_8127.JPG
    Also here I'm working on the shape and fit of the wings rear edge

    IMG_8128.JPG

    IMG_8155.JPG

    I'll come back to this

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

    More glass work to the nose cone top edge and sides, and and front wings. I've used a PU filler designed for top coating fibreglass. Jell coat filler isn't suitable as it's a bit too tough to work on this kind of job.
    Pulled out for sanding.

    IMG_8159.JPG

    IMG_8161.JPG

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

    One of the problems is that I keep noticing stuff that just isn't right. One of those things is the moulded ducts/vents on the arches. None of them match their pair. differences in depth, surround width, surround sweep/shape and overall shape. I suspect there were a few sets of moulds made and over the years they got a bit mixed up so the kits didn't match. That said i never noticed before, maybe an older more critical eye.
    Coming up with a fix for this took some head scratching. My answer was high density black foam coated in the brown non stick tape and moulded into position and held with double sided tape. Fortunately I had some of this tucked away from something else i was doing. Bonus was it was the perfect thickness to match the deepest vent so I just needed to bring all the surrounds up to level with the moulds.

    IMG_8192.JPG
    Front vent lined with non stick tape. Also working on the rear edge of the wing here still

    IMG_8193.JPG

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    Rear vent, the worst, different profile, sweep and depth, with the moulding fixed in

    IMG_8201.JPG
    Front again with the glass laid on drying before mould removal and shaping
    IMG_8202.JPG

    Rear left vent with the glass laid drying before shaping
    IMG_8203.JPG

    Rear right vent was fairly good, but still some wall/surround definition needed
    IMG_8204.JPG

    Rear left vent shaped, just the mould to remove.
    IMG_8235.JPG

    They all match now and are just awaiting finishing to the inside edge and a bit of PU filler to smooth

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

    Front in takes also needed some re working, here I had to choose which profile I liked most, which was the left side, however that would mean removing material from the right to make the match, so decided it was safer to reshape the left side, adding glass rather than removing from the right. If i'd weaken the arch now or gone through the wall, repairing it would be a right bugger.
    Both sides have had some PU filler to better define the shape.
    IMG_8196.JPG

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

    More shaping and sanding.
    Here I'm working on the nose cone top edge, nose cone to wing joins, the wings, RH side of the bumper re profiling and bumper indicator apertures. So often see wonky indicators with excessive gaps around them. That was just so it was easy on the production line to fit, I've tightened that all up.

    IMG_8195.JPG

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

    This little lot has gone off for cleaning and powder coating, and i collected my wheel backs and centres now powder coated and am awaiting the front rim from polishing
    Cross member had a couple of repairs where it's been knocked about over the last 40 odd years, and the bolt holes tidying up by welding and filing into nice ovals. The rear dampers are just getting a clean, I'm not using them but they are in good order, just need to be made tidy.
    ATTACH=CONFIG]85883[/ATTACH]

    IMG_8249.JPG
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Aero catches fitted

    IMG_8322.JPG

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    IMG_8321.JPG

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

    This is a fairing I've made to smooth out the area between the front bib spoiler and the bottom of the front panel. This is all part of a plan to improve air flow around the car. Not talking Ferrari air flows, but create a smooth low pressure air flow under the car, this will involve a removable extension to the bib spoiler. There's a good reason to this but it's too late to include here now.
    Mould one half.
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    Glass laid in
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    Was then fitted to the car to dry and then removed from the mould
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    Other side done the same.

    Here's the underside with the front spoiler modified with the flange widened and the wheel arch extension I showed earlier combined in to that.
    IMG_8448.JPG

    Two halves of the fairing where cleaned up fitted and joined together
    IMG_8450.JPG

    And here it in in place, maybe a bit tricky to see.
    IMG_8449.JPG

    Still work in progress on this, the rear fixing rail is there, a standard RS2000 lower nose cone bracket, I've still got the front fixings to do, I'm using M6 panel fixings, and the bottom surface is going to be finished using glass tape.
    Back soon to finish this update

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

    She is taking shape nicely and tidy as ever

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

    Quote Originally Posted by donnie View Post
    She is taking shape nicely and tidy as ever
    Thanks Donnie. How's progress on yours ?? Hope all's well.

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

    The wing walls now at 90*
    IMG_8607.JPG

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

    Wasn't happy with the bonnet spring section of the pattern slam panel, it lacked definition on the "U" shaped pressing and just isn't as well made as the original, so I swapped it with the original from the old section
    IMG_8536.JPG

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

    Id have thought using stainless steel fasteners would cause alot of corrossion due to disimilar metals, galvanic corrossion, i dont use anything stainless unless its well insulated.

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

    Quote Originally Posted by Erikmex View Post
    Id have thought using stainless steel fasteners would cause a lot of corrosion due to dissimilar metals, galvanic corrosion, i don't use anything stainless unless its well insulated.
    Its personal choice, but having used stainless fixings and fittings into both steel and aluminium assemblies on motorcycles exposed to 'all year road use', without any more significant corrosion compared to using steel on steel or zinc plated on steel for example. Maybe extensive corrosion 'evidence' stems from use in marine applications where the additional sea water electrolyte will have greater effect?

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

    Any liquid will form as an electrolite, even air mositure will to a lesser degree, alot of it depends on stainless grade but disimilar metals such as mild steel to stainless will always set up ectrolosis, with the less noble (in this case mild steel) becoming sacraficial, i would always insulate disimilar metals, even if thats just paint on the raw steel but thats tricky when fitting a rivnut. The other issues with stainless fasteners - although not in this case - is that they will come loose more easily, clamping force is redcued due to the material being far less elastic...more prone to shearing also....but again not in this application, thats why i dont use them on anything engine related.
    Last edited by Erikmex; 07-08-2020 at 10:26.

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

    I've been racing 20 years and in the bike trade for longer, always used stainless fasteners without issue in alloy, steel, mag etc.
    I know the bobblehats theory going on specs etc meaning more risk of corrosion and less strength etc, but in reality it much rather try and remove a stainless bolt from a rusty shit box than an oem steel one

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

    Lucky,ive seen so many corrossion issue and failures with using them over the years, its likely they are easier to remove given the threads (non stainless side) are wasting. Im not suggesting using raw steel fasteners, more quality plated ones, Retropower did a good article on it a few weeks ago too. Do you have any photos? Galvanic corrossion isnt theory BTW.
    Last edited by Erikmex; 07-08-2020 at 12:03.

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

    Quote Originally Posted by Erikmex View Post
    Galvanic corrosion isnt theory BTW.
    Maybe - but show us pictures / some definitive proof that it is worse than 'normal corrosion' ie pictures of a test with steel bolt into a steel nut, exposed to the atmosphere against a stainless bolt into a steel nut, done at same time and exposed for similar length of time - either long term or accelerated test exposure. Also add a zinc plated /passivated bolt and steel nut into the test would be useful.

    The fact is, not many people assemble fixings 'dry' and either use - oil / grease / assembly lube / thread locker on threads so chances of galvanic corrosion are minimised to insignificant levels. Still - each to their own.

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