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Thread: Mk1 Escort Zetec

  1. #1

    Mk1 Escort Zetec

    Thought it's about time I posted the resto and Zetec engine swap of my Mk1
    Made the decision to find a good restored shell rather then spending the next two years or more starting from scratch again, did make a change not to have anymore welding burns and eye injurys
    The shell started life as a std 1100 had been reshelled at some point using a later ford service shell with most of the extra type 49 strenghtening.

    Have to sort out a pic of the body tag someone might be able to give me some info on the shell.

    Some pics to start with of the restored shell done by the previous owner about 5 years ago
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  2. #2

    Re: Mk1 Escort Zetec

    Few more
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  3. #3

    Re: Mk1 Escort Zetec

    Found some more pics of the escort before I started messing with it
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  4. #4
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    Re: Mk1 Escort Zetec

    lovely looking car mate
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    Mechanic mk2 wizard's Avatar

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    Re: Mk1 Escort Zetec

    Thats nice

  6. #6

    Re: Mk1 Escort Zetec

    Thought it would be a good time to upgrade the brakes and do some basic suspension mods before starting on the engine, it helps if can stop and go round corners.


    The escort already come with Gaz inserts roller top mounts and rear bilstein shocks also had the benefit of a bias pedal box fitted this just needed setting up to correct the brake balance. The std copper pipe was binned and replaced with braided hose and ends.

    Twin cam anti roll bar with double width kit, this stopped the annoying habit of the anti roll moving through the std bushes on full lock


    Wanted to change the princess calipers to something better but I knew I would be skint with the engine [FONT=Arial]change, so ended up using a spacer kit and 257mm cross drilled discs from Rallydesign. [/FONT

    Rear sierra calipers with solid fiesta discs machined down to fit under the 13inch rs alloys

    Panhard rod with the fixed tower with a small extension welded on to get a bit more adjustment,







    Last edited by eric; 05-01-2009 at 21:22. Reason: no pics

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    Re: Mk1 Escort Zetec

    Nice project

  8. #8

    Re: Mk1 Escort Zetec

    Next lot of various pics lsd build up,you lot bored yet
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    Re: Mk1 Escort Zetec

    very nice

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    Re: Mk1 Escort Zetec

    im not bored is that a slipper mate? have u done all this already or are u just working really fast haha
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    Re: Mk1 Escort Zetec

    nice where did you find that

  12. #12
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    Re: Mk1 Escort Zetec

    Nice project

    Do you live in Kent by chance? that pic of yours next to the black mk2, that was at lydden, easter 07

    Looking forward to the progress and updates

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    Re: Mk1 Escort Zetec

    I parked next to that mk2 up at the supermarket by pod the other year at cf show my car made looked shit next to it, yours fits in a treat!!

    Nice work keep the pics coming

  14. #14
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    Re: Mk1 Escort Zetec

    Beautiful car mate.

    I did not realise that it was possible to put princess 4 pots behind the 5.5" std MK1 rims but it looks like you have been able to do so?

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    Re: Mk1 Escort Zetec

    Do the Princess calipers fit directly to the upright or did you need an adapter?
    Reason for asking is that the Princess caliper is direct bolt on for my MGB, but if it's also direct bolt on for the Escort I can use Escort kits on my MGB - and that makes the selection of brake upgrades a lot bigger
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  16. #16

    Re: Mk1 Escort Zetec

    Quote Originally Posted by Jamie_mk1 View Post
    im not bored is that a slipper mate? have u done all this already or are u just working really fast haha
    Got 2 cases of redbull for xmas works wonders with any Escort

    Yep found a lsd for 175 needed some love now works fine.

    The Escort has being up and running for the last few months never had the time to post this.
    Last edited by eric; 06-01-2009 at 18:57.

  17. #17

    Re: Mk1 Escort Zetec

    Quote Originally Posted by HERBY View Post
    nice where did you find that
    Looked all over the place for ages to find a good escort and ended up buying the escort locally off Pistonheads.

    Quote Originally Posted by Mk1_Deano View Post
    Nice project

    Do you live in Kent by chance? that pic of yours next to the black mk2, that was at lydden, easter 07

    Looking forward to the progress and updates
    Yep not far from lydden always try to get to see as many events as poss

    Quote Originally Posted by dangerousdave View Post
    I parked next to that mk2 up at the supermarket by pod the other year at cf show my car made looked shit next to it, yours fits in a treat!!

    Nice work keep the pics coming
    That was jeffs mk2 Mexico one of the best

    Quote Originally Posted by DPM View Post
    Beautiful car mate.

    I did not realise that it was possible to put princess 4 pots behind the 5.5" std MK1 rims but it looks like you have been able to do so?
    Quote Originally Posted by Sonus View Post
    Do the Princess calipers fit directly to the upright or did you need an adapter?
    Reason for asking is that the Princess caliper is direct bolt on for my MGB, but if it's also direct bolt on for the Escort I can use Escort kits on my MGB - and that makes the selection of brake upgrades a lot bigger
    The Princess caliper fits directly to the escort struts with the 257mm discs, no adapters there are some washers which may be needed to give the correct caliper to disc clearance, 13 inch wheels no problem.

    The only problem with the cast iron princess caliper it retains heat so brake fade can be a problem when used hard, but it still is affective budget setup.
    Last edited by eric; 06-01-2009 at 19:41.

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  19. #18

    Re: Mk1 Escort Zetec

    Having made my mind up on the zetec engine thought I better go shopping for a phase 3 engine this is the more expensive engine to use due to the water pump rotation, reason for the later unit being improvements to the bottom end including slipper pistons, larger inlet valves worth 5bhp, oil jets to provide under-piston cooling, new injectors end fed unlike the side fed early injectors which are not compatable with jenveys,these later injectors will cope up to 185bhp@3bar so don't bin them until you go for more power.

    Solid tappets with adjustment shims replaced the hydraulic lifters and revised cam belt timing tensioning setup. The pistons are teflon coated to reduce friction, water pump comes with large vanes for improved flow also the block was strengthened, a larger amount of metal between the bores which is clearly visible when compared to early phase 1 and 2 engines.

    The zetec engine was from a 1999 2.0ltr mondeo automatic (stop laughing)

    So one ebay purchase later,

    the sump and engine mounts are from Retro ford, well made and no issues with alignment.
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  20. #19

    Re: Mk1 Escort Zetec

    Battery tray removed and trail fit of the zetec, decided to use the raceline water rail.

    All the braided brake lines had been finished at this stage.
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  21. #20
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    Re: Mk1 Escort Zetec

    awesome mate. have you got any picks with the alternator kit installed showing all the pulleys? i have to do mine at the weekend...
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  22. #21

    Re: Mk1 Escort Zetec

    Got this one of the pully arrangement,idle pulley and alternator kit from raceline, not cheap but top quailty stuff.

    http://www.raceline.co.uk/products/p...0&CategoryID=4

    http://www.raceline.co.uk/products/p...8&CategoryID=4

    Here's a pic of the complete setup
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    Last edited by eric; 06-01-2009 at 22:59.

  23. #22
    Pit Crew Decade Plus User PaulAlex's Avatar

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    Re: Mk1 Escort Zetec

    Lovely looking install

  24. #23
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    Re: Mk1 Escort Zetec

    ive got the retro ford kit. looks the same sort of set up though
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  25. #24

    Re: Mk1 Escort Zetec

    Quote Originally Posted by Jamie_mk1 View Post
    awesome mate. have you got any picks with the alternator kit installed showing all the pulleys? i have to do mine at the weekend...
    Jamie a better pic (not my engine)
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  26. #25

    Re: Mk1 Escort Zetec

    Thanks for all the nice comments

  27. #26

    Re: Mk1 Escort Zetec

    Quote Originally Posted by Jamie_mk1 View Post
    ive got the retro ford kit. looks the same sort of set up though
    Dave does make some very high quality stuff for the zetec,
    do have you any pics of the pulley setup from retro ford

  28. #27
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    Re: Mk1 Escort Zetec

    ill try and fire some up at the weekend for u mate. its not too bad dont think its quite as quality as the raceline stuff but it was a fraction of the price
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  29. #28

    Re: Mk1 Escort Zetec

    Cheers mate, best of luck at the weekend

  30. #29
    Pit Crew Decade Plus User 105Ian's Avatar

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    Re: Mk1 Escort Zetec

    Very nice looking bit of kit

  31. #30
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    Re: Mk1 Escort Zetec

    Looks brilliant, well done

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  32. #31
    Mechanic MCURZON's Avatar

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    Re: Mk1 Escort Zetec

    Lovely looking car, great work.

    Matt

  33. #32
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    Re: Mk1 Escort Zetec

    Lovely job you done there, keep up the good work

  34. #33
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    Re: Mk1 Escort Zetec

    really nice looking car

  35. #34

    Re: Mk1 Escort Zetec

    After the zetec was checked for any fitment problems it was then time to sort out the flywheel and gearbox. Used a 1.8 zetec flywheel machined to accept the pinto clutch, the std clutch cable was used with a retro ford bracket for the g/box, well pleased with this setup.

    Had my son machine a steel guide to bolt dead centre of the flywheel and machined to the inner diameter of the pressure plate, this gave perfect alignment for the drilling of the flywheel dowels and pressure plate bolts. available for hire for a small fee

    I am a big fan of the 4 speed type rocket box, but still using the std gears at the moment, the internals will be changed to tran-x or quaife gears asap as the std box don't seem to last very long, already on box number 3 in as many months, still that's my fault for thrashing the crap out of it

    Next was the exhaust, looked at ashley and others but when it comes down to it threre's not a lot of choice for the zetec. I wanted a 4-2-1 manifold could'nt find any so had
    Zero exhaust make a one off system, made from grade 304 stainless steel top quality system and sounds the nuts

    Zero made a copy of the manifold if anyone is interested http://www.zeroexhausts.co.uk/

    Some pics
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  36. #35

    Re: Mk1 Escort Zetec

    One more
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  37. #36

    Re: Mk1 Escort Zetec

    From Zero's web site, last one promise
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  38. #37
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    Re: Mk1 Escort Zetec

    Woohaa...... that's one expensive manifold - 450?
    Last edited by Sonus; 07-01-2009 at 21:24.
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  39. #38

    Re: Mk1 Escort Zetec

    Quote Originally Posted by Sonus View Post
    Woohaa...... that's one expensive manifold - 450?
    Was a bit mad, can't help myself when it comes to buying stuff for the escort

  40. #39

    Re: Mk1 Escort Zetec

    Started working on the fueling, sorted the pumps, filter swirl pot goodridge fuel hose and fittings.







    Swirl pot fitted and some fuel hose plumbed in.



    High pressure pre filter and pump out of the way under the floor.





    Fuel lines all sorted



    Fuel pressure controlled by a bling regulator



    Yum

  41. #40
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    Re: Mk1 Escort Zetec

    nice work mate how much was the regulator?
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