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Thread: Mark 1 Escort with YB Cosworth in Aus

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    Mark 1 Escort with YB Cosworth in Aus

    I have a Mk1 coupe shell, plus these bits:

    Fuel injected 8 injector n/a YB cosworth engine
    dry sump system
    quaife 5 speed gearbox
    floor mounted pedal box
    adjustable lower control arms
    steel forest arch flares
    MoTeC M800 ECU, PDM and Dash
    Group 4 kit

    Some images of the before

    This is the car when I got it.



    Here is the engine as it is going in the car



    Here is the car as it is now.




    The engine was just going to get a freshen up and put in the car, but the rebuild has found that 10 years of racing the engine has worn it a little, so down for a rebore on the 205 block, and some new custom pistons.

    The pistons getting made by Pure Performance in Dandenong. What a nightmare to deal with. 18 months for a set of pistons.

    The pedals are from a Panoz Lemans car.

    Engine rebuild started, needed new pistons. Ordered them (needed to be custom made) Told 6 weeks for delivery, pay up front. Delivery ended up around 18 months.More engine work still in progress.

    In a bigger change, I sold the yellow shell to a guy building a Mk1 Tarmac rally car. I did this as I had found a car in better condition, that had already been sand blasted and was further along that my car was.

    I have bought some Gaz rear coil over dampers for the turret rear end going in the car (not the best, but good enough)

    So now the car body work has finally begun!




    Hopefully the body work is complete towards the end of the year.
    Attached Thumbnails



    The bodywork has moved along:








    The front suspension is mostly together



    And the new display layout is coming together.




    the YB engine is together, but during final assembly the thread pulled out of the head where the belt tensioner is... this has put the engine back a little whilst we try to repair the head.

    Brand new front guards have been sourced and are currently being modified to add the steel flares to them.

    Still hoping to be running by the end of this year.

    jamie

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Thats going to be a nice car...has the engine been in a mk1 escort ...looks like it will be close on the injectors...love it still...cheers mark

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Good luck with the project

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    Re: Mark 1 Escort with YB Cosworth in Aus

    yes, the engine was originally in my Mk1 Escort Race car, this one:
    car55sml.jpg
    100_0544 sml.jpg
    scrtback sml.jpg

    Might have some bonnet clearance issues, going to have to re-do the air box at the minimum...

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    Re: Mark 1 Escort with YB Cosworth in Aus

    nice..yes i can see the bonnet bulge...will be great...kepp the photos coming.cheers mark

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    Re: Mark 1 Escort with YB Cosworth in Aus

    More progress, the car feels like it is finally coming together body wise.

    4 link kit, watts link and turrett dampers are in.

    the diff has been modified for the floaters, and the arm mounts.

    The wheel fits and is just inside the guard.

    20170730_163523sml.jpg
    20170731_180609 sml.jpg
    20170731_180655 sml.jpg
    20170731_180708 SML.jpg
    20170731_180953 sml.jpg

    The ride height looks like it will be a little high at the moment, need to look to see what it hits first when it gets lowered.

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    Mark 1 Escort with YB Cosworth in Aus

    Nice work mate 👍🏻I'm now at the turret/link fitting stage with mine.. just out of interest what measurement did you take to put in the turrets. Want to make sure mine are right. Cheers


    Sent from my iPhone using Tapatalk

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Jamie what happened to the old car?

    JP

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    Re: Mark 1 Escort with YB Cosworth in Aus

    the old car got sold to a guy who is turning it into a rally car in Aus, and I used that money to buy the black one.

    It was a good shell, but the black one was better.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    arent your steering arms on the wrong way round?

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    Re: Mark 1 Escort with YB Cosworth in Aus

    yes, they might be

    I have never used this type of strut before, and have yet to fit them to the car.

    so I guess I would have worked that out when I tried fitting them up... hopefully.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Jamie, Is this the same engine from all those years back?

    I remember reading about this engine waaaaaaaaaay back in the spanner fodder forum days and being jealous.

    I take it you still work for motec?

    Are you still racing?
    Shaun

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    Re: Mark 1 Escort with YB Cosworth in Aus

    yes, the same engine but has just had a full rebuild after sitting in the garage for maybe 10 years.

    when I sold the race car, I pulled out the engine and gearbox, and put an SR20 in it. The engine was worth too much to sell in a race car. I had always intended to put it in a car that I could drive regularly.

    So here we are. Finally. about 6 months away (I think) from the realization of an idea from 10 years ago.

    so yes, I am still working at MoTeC, so the car is going to have all of the latest electronics on it.

    Previously I built up a Volvo P1800s to original spec. To me it looked great...

    FR Sml.jpg

    but it drove like a car from 1960 (as expected). so it wasn't much fun.

    So this escort road car isn't going to be a sympathetic restoration or anything like that. it is going to be a car that I actually can enjoy driving.

    So fuel injection, good seats, I have 6 piston calipers for the front brakes, etc etc.

    A fully modern Mk1 escort this time.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    after almost 3 years being rebuilt, the engine finally came home today ready to go in the car...

    DSC_2102sml.jpg
    DSC_2103sml.jpg
    DSC_2104sml.jpg
    DSC_2105sml.jpg

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    Re: Mark 1 Escort with YB Cosworth in Aus

    to finally fix the lack of front guards (the yellow car guards were too rusted, the black car had fibreglass ones) I bought a pair of new standard Mk1 guards and I already had the steel flares.


    front guard sml.jpg

    the first one is almost finished.

    the Pedal box is now in the car, pictures to come.

    So it is time for the car to come home and start the assembly process...

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Time to install the hydraulic centre push throw out, the flywheel, clutch and then put the Quaife gearbox on the engine. Sounds simple, but that isnt how it turned out.


    So mock up the centre throw out and lines
    hydr sml.jpg

    cut, install and finish the lines
    hydr fin sml.jpg

    Install the flywheel and clutch on the engine
    clutch ready sml.jpg

    try to fit the gearbox to the engine, and it wont fit....

    this doesnt look right, the input shaft is too long....
    opps sml.jpg

    hmmm that is a bit of an issue.
    input sml.jpg

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    Re: Mark 1 Escort with YB Cosworth in Aus

    2.8 input shaft?

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    Re: Mark 1 Escort with YB Cosworth in Aus

    yes, talked to quaife, it is the long input shaft. only $500 later and a short shaft is on the way.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Quote Originally Posted by Cossie55ish View Post
    yes, talked to quaife, it is the long input shaft. only $500 later and a short shaft is on the way.
    maybe this would have helped, great build though

    http://www.retro-ford.co.uk/shop/content/gearbox-spacer-kit-28-capri-gearbox-drt001

    Last edited by wildo105e; 18-10-2017 at 21:25.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    yes, that would have worked, but then I would need to space the clutch centre bearing forward 10mm to work, the tailshaft would need shortening (maybe) and everything else like gearbox mounts would end up in the wrong spot.

    So I considered that, but thought that the trickle down of other items made it not worth doing.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Quote Originally Posted by Cossie55ish View Post
    So I considered that, but thought that the trickle down of other items made it not worth doing.
    Fair enough

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Finally the Typ3 9 gearbox has a new input shaft, $700 later and I now have a better understanding of how to build gearboxes.

    I have mounted it on the engine:
    DSC_2391sml.jpg

    then I thought I would check on the throw out clearance... that isnt going to work... now I have to buy a spacer from burton to fix this clearance issue up!
    DSC_2402sml.jpg

    Ignoring that issue, it was time to put the engine in the car, but before that, thought I would put the new struts on the car to see how they look.
    DSC_2405 sml.jpg

    Now with the engine in the car, and the gearbox bolted up, it has started looking slightly like a car!
    DSC_2434 SML.jpg

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Jamie,
    I think you'll need a rounded nose throwout bearing for that clutch.
    one in your photo looks flat faced

    WP_20131103_004_zpscf9dacb0.JPG

    JP
    Last edited by jpblue; 20-11-2017 at 21:49.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    mine is rounded, but not as much as yours, it came from burton power. The problem is the gap between the bearing and the clutch fingers. the gap is too big, and the hydraulic throw out will not extend that far.

    so I ordered the 25mm spacer from burton to move it closer to the clutch.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    I am sure you are all over it but remember that as the clutch plate wears the fingers move towards the bearing = dont set the initial clearance too close else the clutch will slip as it wears.
    1970 Mk1 Escort Tarmac Rally Car

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Thanks, I will keep that in mind. I had trouble really accurately measuring the spacer that I needed, so I ordered the 25mm one. Once that is in, I will have to measure again and possibly machine it shorter to get it just right.

    Do you have any idea what the ideal clearance should be ?

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Another delivery from Motorsport tools, another issue. I am starting to lose confidence in their ability to supply products that actually fit.
    rack end sml.jpg
    after much stuffing around and pulling apart of racks, the conclusion is that the rack ends that I bought new from motorsport tools have shrunk during hear treating and wont fit the quaife quick rack (or any of the 3 factory racks that I have tried). time to again fix the parts that arrive from there.

    front guards have been dummy fitted, and look great.

    FL with guard.jpg

    FR with guard.jpg

    front with guards.jpg

    now if I only had a rack...

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Quote Originally Posted by Cossie55ish View Post
    Do you have any idea what the ideal clearance should be ?
    Being hydraulic, any clearance will be taken up by the hydraulic system. The things to actor in are;

    1. the amount of (safe) travel on the slave piston
    2. how much the fingers need to be moved forward in order to release the clutch
    3. how much the fingers will move rearward as the clutch plate wears (I measured the 'thickness'of the rivets then put some stell of that thickness against the flywheel rather than the friction plate so I could measure the inger movement

    The way I see it, the initial clearance needs to be a small amount more than the amount by which the fingers move due to friction plate wear but not too much that the slave doesn't have enough stroke.

    Also ensure your M/C is correctly sized for the clutch or ensure you have a good clutch pedal stop. I have over-stroked my slave several times which is a PITA.
    1970 Mk1 Escort Tarmac Rally Car

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    Mark 1 Escort with YB Cosworth in Aus

    Quote Originally Posted by MK1_Oz View Post
    Also ensure your M/C is correctly sized for the clutch or ensure you have a good clutch pedal stop. I have over-stroked my slave several times which is a PITA.
    Agree been there as well 😡

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Finally got to looking at the rear end of the car whilst waiting for Motorsport tools to work out what is wrong with the steering parts.

    Got the brand new plate LSD out of the box, and went to install it. Good bit of gear, they even provided bearings (sometimes it is the little things!)
    diff sml.jpg

    All bolted in, lock wired and ready to go.


    so put the diff in the car. Now time to put the new floating axles in the diff.
    I think there is a problem here (that is all the way home!)

    axle too long.jpg

    Looks like quaife supplied the 820mm long atlas axles instead of the 730mm english axles..
    Another day, another screwup.

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    Mark 1 Escort with YB Cosworth in Aus

    It would annoying if in Britain never mind the other side of the world.

    Stick with it 👍

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    Re: Mark 1 Escort with YB Cosworth in Aus

    wow...so unlucky...dont get down..it is looking great...cheers mark

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Jamie,

    Isn't 'escort' the aboriginal word for doesn't fit first time or without modification!
    Ive found the suppliers are usually pretty good with swapping parts over, the pain being the time and additional cost. Do a deal with quaife and have them shortened and splined locally

    JP

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    Re: Mark 1 Escort with YB Cosworth in Aus

    I am coming to the UK to work on the MoTeC stand at Autosport, to hoping to do a swap of the wrong axles for the right ones at the show... fingers crossed they have them in stock.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    How big is your suitcase? Can we put in orders?
    1970 Mk1 Escort Tarmac Rally Car

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Well at this point, I am nowhere, as Quaife have not replied at all and Motorsport tools don't seem to understand the issue... Looks like the Midnight calls from aus are going to start tonight.

    as for bag size, well I think weight is the bigger issue as I expect to be swapping some axles over!

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Looking good

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Quote Originally Posted by Cossie55ish View Post
    Time to install the hydraulic centre push throw out, the flywheel, clutch and then put the Quaife gearbox on the engine. Sounds simple, but that isnt how it turned out.


    So mock up the centre throw out and lines
    Attachment 81729

    cut, install and finish the lines
    Attachment 81728

    Install the flywheel and clutch on the engine
    Attachment 81725

    try to fit the gearbox to the engine, and it wont fit....

    this doesnt look right, the input shaft is too long....
    Attachment 81726

    hmmm that is a bit of an issue.
    Attachment 81727
    You could have machined the input shaft shorter. I have done it in the past.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    Quote Originally Posted by Cossie55ish View Post
    Time to install the hydraulic centre push throw out, the flywheel, clutch and then put the Quaife gearbox on the engine. Sounds simple, but that isnt how it turned out.


    So mock up the centre throw out and lines
    Attachment 81729

    cut, install and finish the lines
    Attachment 81728

    Install the flywheel and clutch on the engine
    Attachment 81725

    try to fit the gearbox to the engine, and it wont fit....

    this doesnt look right, the input shaft is too long....
    Attachment 81726

    hmmm that is a bit of an issue.
    Attachment 81727
    You could have machined the input shaft shorter. I have done it in the past.

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    Re: Mark 1 Escort with YB Cosworth in Aus

    the splines were not long enough.
    there wouldn't have been any spline engagement in the clutch plates.

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