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Thread: My New Project ( Millington Escort) to stop me using this

  1. #561
    Spanner Monkey genRS2000's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Well it is 38C here in Western Australia today so I thought it would be a good time to update this thread.

    I have competed in 9 events in the first half of this year and then temporarily retired the car to give it a makeover.

    There were some new events this year because the club that runs the local racetrack have added a link road between the circuit and the adjacent hillclimb so that what they call Point 2 Point sprints could be run. They are very similar to the rally stages run at UK racetracks but being sprints a co-driver is not required and only one layout was used for each event which consisted of a practice and 3 timed runs.

    Five events were run and my car seems to be very suited to them as my results were 2 firsts, 2 seconds and 1 third. I really liked these events as they reminded me of my rallying days in the 80s (also in an Escort).

    Here are a couple of videos:





    Two more videos, a very short hillclimb and sprint run on the tarmac stage of the Western Australian round of the Australian Rally Championship.







    One of the questions I am often asked is why the car has such small wheels ( these days anything under 17in seems to be considered small!). The reason is that I like the look of wide 13in Minilites.
    I gave my motorsport engineer friend a drive of my car at a sprint last year and he also queried the small wheels so I decided to change to 15in wheels to shut everyone up!

    I have always loved the wide arched Zakspeed Escorts with BBS wheels so this is what I have chosen to replicate.I have not aimed to have an exact replica and will have essentially the same colour scheme as before.



    Initially I thought that it would be completed in about a month after I started the change but it has dragged out to over 4 months because it has been more complicated than I thought it would be.

    Next post I will start detailing the process......complete with lots of photos

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  3. #562
    Mechanic Matt75's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Hey Mate,

    Great work as always

    If you haven't bought wheels yet, have a look at these as they are what I bought. Great price and very easy to deal with

    https://braidusa.com/collections/whe...=4880759783466

    Cheers

    Matt

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    Spanner Monkey genRS2000's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    I have the wheels Matt. I did look at Braid and Image but settled on BBS like the original Zakspeeds.

    One of my motorsport friends has some 13in BBS three piece wheels on his Capri so he put me in touch with Klaus at BBS Motorsportrader in Germany. After a few emails being sent back and forth and me parting with a lot of Euros I ordered two 9 1/2in for the front and two 10in for the rear.
    I needed the wheels to be machined to accomodate my Group 4 stud inserts and Klaus was able to do this. He gave a delivery time of three months but this dragged out to five months.
    The wheels arrived disassembled , the halves in one carton and the centres, seals and bolts in another. They are beautifully made, I just had to fit the inserts and they bolted straight on.
    I had tried some Michelin TB5 soft compound tyres for the Point 2 Point sprints and was very impressed with the grip so I ordered two 270/45R15 for the front and two 285/40R15 for the rear from Longstone tyres in the UK.









  5. #564
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    Re: My New Project ( Millington Escort) to stop me using this

    After making the decision to change to the Zakspeed look I had to source a body kit. After scouring the internet I found three sources for the X pack body kit, two in the UK and one in Australia. The one in Australia was no good because they only did the arches and not the front panel/spoiler.
    The UK ones were Fibresports and Smith and Deakin. Fibresports was ruled out because they don't make them anymore even though they are still listed on their website. I assumed that they had replaced the moulds that were destroyed in the fire at their factory. This left Smith and Deakin as the only choice.
    I ordered the full kit with combined front wings and arches (this was a mistake as I will explain later). Again the quoted delivery time dragged out because Mike, the guy making it became ill. I eventually received the kit in March after ordering it in December 2017.

    On initial inspection the quality looked reasonable.(Sorry, I did not take any photos). The rear arches fitted very well but the front wings would need quite a lot of work to get a good fit and how the spoiler part of the front panel would fit onto the wing was beyond me.

    Anyway this was all academic because I soon realised that the arches weren't going to be wide enough the cover the wheels/tyres so the only option was to widen them.
    This is where getting the combined wing/arch was a bad decision because I was going the have to cut the arch section from the wing to insert a section to make the arch wider. In fact I did cut the arch off but used the original steel wing because I was not happy with how the fibreglass wing fitted.



    Front wings and rear alloy tarmac arch removed.





    Rear arches offered up the determine how much extra width was required although at this stage I had not received the BBS wheels so I had to wait until I could get an exact measurement.





    I cut a section off the front wings to allow the fibreglass arch to be fitted.



    Mocked up to get the extra width measurement.



    I will say that all this took a get deal of time to work out as I did not want to get it wrong.

  6. #565
    Mechanic Matt75's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    I love a good Zakspeed!! I have done a Grp 2 replica

    Very Very nice work and very ambitious like everything else you've done!

    Will you make a rear wing or keep the one you have?

    Great stuff as always

    Cheers,

    Matt

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    Spanner Monkey genRS2000's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by Matt75 View Post
    I love a good Zakspeed!! I have done a Grp 2 replica

    Very Very nice work and very ambitious like everything else you've done!

    Will you make a rear wing or keep the one you have?

    Great stuff as always

    Cheers,

    Matt
    I have been following your Grp 2 Matt. I think that is where I got to know about the Braid wheels.

    I don't want a high wing but am toying with the idea of making the one I have now a bit bigger.

    Sometimes I wonder why I set myself these challenges

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by genRS2000 View Post

    Sometimes I wonder why I set myself these challenges
    Lol, I hear you mate


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    Spanner Monkey genRS2000's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Widening the rear arches was going to be easier than the fronts so started on them first. At this stage I had received the wheels so I could get an exact measurement for the widening.

    I bought a piece of zincalume building flashing and bent it to fit between the arch and the body.






    Because the body is curved I made some cuts in the insert to follow that curve.




    The insert was glued on with Sikaflex. Bolts were welded onto the insert to attach the arch to the body.



  10. #569
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    Re: My New Project ( Millington Escort) to stop me using this

    I had to fill in the gaps at the front and rear of the arch including curving the top of the ends.



    I thought I would put mesh in the rear sections.



    Aluminium shaped to fit with the edges smoothed in with filler.










    I used an epoxy filler so that hopefully it would not crack.






    Although because it was so strong it was hard to sand down.

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    Re: My New Project ( Millington Escort) to stop me using this

    Hmmm - not sure on those rear arches - front view looks ok but the back look very amateurish and the mesh brings nothing to the party - all looks to wide and boxy. Love the car and what its become but not at the moment - sorry!

  12. #571
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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by katana View Post
    Hmmm - not sure on those rear arches - front view looks ok but the back look very amateurish and the mesh brings nothing to the party - all looks to wide and boxy. Love the car and what its become but not at the moment - sorry!
    Well I am an amateur

    Seriously though, you don't have to be sorry. It is not compulsory to like every part of a project on here...I know I don't.
    The photo does not show the rear at it's best but the arches have now been painted and I put the rears on yesterday and I am very happy with the result BUT I agree with you about the mesh...I actually came to this conclusion before your post! I am going to remove it and maybe try something else.


    The bottoms of the rear arches are attached to the body with simple flat plates althoughI have used better fasteners for the final fixing.



    I thought that would be it for the rears but when I temporarily bolted them on something was not right...more about that later.

    Now I tackled the fronts but first I wanted to correct a couple of things.
    I had used a pattern wing to replace the original RH wing when I initially did the shell but didn't realise that the shape was not correct so I wanted to fix it now. The main problem was the the top section wasn't parallel with the grill which meant that the bonnet sat below the wing line.

    Some cuting,bending and welding has fixed this.








    When I removed the LH wing I found that it would fit better around the scuttle if it was pushed further towards the centre of the car which meant that the mounting flange was sticking out to far. As the flange was rather munted from drilling the spot welds I fabricated a new flange.


  13. #572
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    Re: My New Project ( Millington Escort) to stop me using this

    On to the front arches.

    Aluminium bent and curved and attached to the steel wing





    Fibreglass arch placed onto the insert to get the correct width.





    Steel section fabricated to fill the gap at the front.





    It looks pretty ugly inside but it does the job....my intention is to eventually make same moulds of each arch and make complete fibreglass ones.
    The inserted section was attached to the fibreglass with Sikaflex epoxy glue.





    Ready for filler.


  14. #573
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    Re: My New Project ( Millington Escort) to stop me using this

    One layer of fibreglass reinforced filler, then a fine filler.











    Epoxy filler to cover the rivets that attach the arch to the insert and to smooth the join between the insert and the wing.





    Gap filled in with aluminium and more filler.





    I haven't mounted the front wings yet so I don't know whether the mesh will stay.

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    Re: My New Project ( Millington Escort) to stop me using this

    Wow - trowel that f/glass on - you got shares in the company LOL! Although the rectangular mesh isn't good at the back I do see some use at the front to assist venting hot brakes as they are / will be very in-board of passing air with the big wheels and arches - will you be adding some cooling ducts from front splitter / dam - might be a good idea?

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    Spanner Monkey genRS2000's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by katana View Post
    Wow - trowel that f/glass on - you got shares in the company LOL! Although the rectangular mesh isn't good at the back I do see some use at the front to assist venting hot brakes as they are / will be very in-board of passing air with the big wheels and arches - will you be adding some cooling ducts from front splitter / dam - might be a good idea?
    No shares and I won't be using it again...it was only an experiment. It is like treacle and very difficult to "tool". What I have done to the front will be posted very soon.

    I mentioned before that there was something wrong with the rear arches. The problem was that the top of the arch followed the swage line along the rear quarter panel which made it look too flat. It just didn't look right. The model I am working off has the top curved which looks much better.
    I agonised about this for a few days and concluded I couldn't live with this so I had to change the profile.


    First I got some polystyrene and shaped a section to the profile I wanted. Because there was angle on the panel above the swage line I bent some aluminium to that angle. This was glued to the polystyrene and the polystyrene was glued to the top of the arch.









    I bent some sheet metal to the shape of the arch and filled the gap with filler.





    I was going to smooth some filler over the top of the polystyrene but the filler was melting the polystyrene so I glued a piece of aluminium onto the top.




  17. #576
    Spanner Monkey genRS2000's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Before:



    and after





    That's more like it. Looks much better

  18. #577
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    Re: My New Project ( Millington Escort) to stop me using this

    Some thin plastic sheet used to fill in the gap between the arch and the body.







    Before I fitted them I spruced up the wheel arch with some POR 15.




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    Re: My New Project ( Millington Escort) to stop me using this

    To the front.

    The first thing I had to do was cut the small lip off the bottom of the front panel that was part of the kit because it was not low enough for what I wanted.




    I also had to cut the side pieces off the front panel because they did not line up with the arches.



    I made the rectangular slots in the front panel larger.






    Front panel in place.



    Aluminium to flare the arches into the front panel.





    More filler.





    Needed a lip on the bottom of the front panel to attach a spoiler.


  20. #579
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    Re: My New Project ( Millington Escort) to stop me using this

    Now for the difficult bit.

    I needed to make an aluminium spoiler and I wanted it to be angled out at the bottom like the Zakspeed model which meant I had to do the end bends with high accuracy.
    I started with a short piece to test for the required angle and then I marked that angle on the actual piece for the spoiler.



    I bent it by hand using a bit of pipe as a former.



    Miraculously the bend was correct and it fitted really well.





    The top edge needed a bit a tweeking to get the "cowcatcher" look.



    To give the bottom edge some strength I used some pine timber to create a lip.





    This pine was shaped to give a nice curve. The aluminium under the pine is the part of a splitter which I will detail in the next post.




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    Re: My New Project ( Millington Escort) to stop me using this

    The splitter was made by sandwiching some coreflute between two pieces of aluminium. This made it light but strong.

    This is screwed to the underside of the timber. I don't seem to have a photo of it in place.










  22. #581
    Mechanic Matt75's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Very nice mate, I may steal that idea for my car!!

    Keep up the great work, when's the first race?

    Cheers,

    Matt

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    Re: My New Project ( Millington Escort) to stop me using this

    I do hope you are going to take moulds and reproduce all in larger single panels - as one little mistake, and its a shed load of gaffa tape and sticky back plastic to repair it all ? The splitter looks particularly vulnerable!

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by Matt75 View Post
    Very nice mate, I may steal that idea for my car!!

    Keep up the great work, when's the first race?

    Cheers,

    Matt

    I stole it from the internet although the guy who posted it used a commercially available product that had a plastic and core flute sandwich . He had bought a large sheet of it , I spent $5 on some core flute and used some ally I had.

    There is a hillclimb in early February but I want to do some testing so I will probably wait until March for it's first event.

    Quote Originally Posted by katana View Post
    I do hope you are going to take moulds and reproduce all in larger single panels - as one little mistake, and its a shed load of gaffa tape and sticky back plastic to repair it all ? The splitter looks particularly vulnerable!
    I have already mentioned that I will make moulds of everything. The first will be of the spoiler/splitter combined. The spoiler is attached to the front with 1/4 turn fasteners so that it will be easy to replace it if it gets damaged.

  25. #584
    Mechanic Matt75's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    [QUOTE=genRS2000;3487202]I stole it from the internet although the guy who posted it used a commercially available product that had a plastic and core flute sandwich . He had bought a large sheet of it , I spent $5 on some core flute and used some ally I had.

    There is a hill-climb in early February but I want to do some testing so I will probably wait until March for it's first event./QUOTE]

    Nice one, are you going to make the large rear spoiler too?

    Cheers,

    Matt

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    Re: My New Project ( Millington Escort) to stop me using this

    [QUOTE=Matt75;3487203]
    Quote Originally Posted by genRS2000 View Post
    I stole it from the internet although the guy who posted it used a commercially available product that had a plastic and core flute sandwich . He had bought a large sheet of it , I spent $5 on some core flute and used some ally I had.

    There is a hill-climb in early February but I want to do some testing so I will probably wait until March for it's first event./QUOTE]

    Nice one, are you going to make the large rear spoiler too?

    Cheers,

    Matt
    I have. I will be painting it this week.

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    Racer Decade Plus User wildo105e's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    http://forum.retro-rides.org/thread/...quickest-legal

    this may be of interest. This guy has done a lot of carbon panels himself. Whole post is a good read though..

    Good work.

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by wildo105e View Post
    http://forum.retro-rides.org/thread/...quickest-legal

    this may be of interest. This guy has done a lot of carbon panels himself. Whole post is a good read though..

    Good work.

    That looks interesting, I will have a read of it when have time.

    A local guy who is following my build has offered to help make the moulds as he has some experience doing this and another guy who does the same events as me has experience with carbon fibre which he will share.



    Bigger wheels and tyres means clearance problems at the front. The tyres foul the footwell on full lock and when the suspension is compressed.

    I did not want to raise the ride height so I had to cut part of the foot wheel out and fill in the hole with aluminium, carefully beating it into shape with a soft hammer.







  29. #588
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    Re: My New Project ( Millington Escort) to stop me using this

    Pretty sure you wouldn't get away with pop rivoting that plate in the footwell over here, it would need to be welded in. Bit more of a pain but could you not get some 15" footwell bowls for it?

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by rallyrob View Post
    Pretty sure you wouldn't get away with pop rivoting that plate in the footwell over here, it would need to be welded in. Bit more of a pain but could you not get some 15" footwell bowls for it?
    The rivets won't be a problem and it is also Sikaflexed

    If I wanted to do any welding in the footwell area I would needed to move all this:



    and I definitely wasn't going to do that, hence the riveted ally. The amount that needed to be removed from the body was minimised because I had converted the compression struts to be in-situ adjustable which meant I could wind the wheel forward to "fine tune" the gap between the tyre and the body.

    A couple of months ago a bought a lathe so I was able to modify the compression struts myself.








    Bigger wheels means bigger brakes so I now have these:



    The discs are 304mm x 28mm








  31. #590
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    Re: My New Project ( Millington Escort) to stop me using this

    What a great read.
    When you were considering a kit, did you consider the XXX Pack one as used on mine. Its wider than what you have currently fabricated but would have saved you loads of time in the end.

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by 4parajon View Post
    What a great read.
    When you were considering a kit, did you consider the XXX Pack one as used on mine. Its wider than what you have currently fabricated but would have saved you loads of time in the end.
    I haven't heard of the XXX Pack and it didn't come up when I was searching the internet for a kit.

    A kit like that would have made it easier but it has been an interesting exercise modifying everything and I have been able to tailor it to be the right width for the wheels/tyres I am using and to have something a bit different.



    I thought it would be an idea to have some skirts/running boards (not sure what to call them) between the front and rear arches.

    These were made from aluminium and filled with polystyrene. My sheet metal bender will only take lengths up to 600mm so I had to join two sections together.






  33. #592
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    Re: My New Project ( Millington Escort) to stop me using this

    Read the whole thread over the last few weeks, thanks for taking time to post

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by Turboman View Post
    Read the whole thread over the last few weeks, thanks for taking time to post
    That's OK. Hope you enjoyed reading it.


    Brackets on the front to brace the spoiler at high speed.



    These lock into bosses on the spoiler.




    Now onto modifying the rear spoiler.

    At first I was going to increase the height by glueing polystyrene onto the top and shaping it to the profile I wanted but I thought of a better way.

    That was to cut 3/4 of the way around the top and bending the rear up 50mm.







    The gap was filled with aluminium bent to shape.









    I wasn't happy with 90 angle of the filled gap (because this piece is now hidden I drilled holes for weight saving ) so I made some extra pieces with a curve to make it look better.




    I made the curve by hand bending on a pipe former.











  35. #594
    Mechanic Matt75's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Great stuff. Why not the group 5 spoiler?

    Cheers

    Matt

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    Bodger

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    Re: My New Project ( Millington Escort) to stop me using this

    Amazing work! From start to now!

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  38. #596
    Tyre Wall Terry Decade Plus User 4parajon's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by genRS2000 View Post
    I haven't heard of the XXX Pack and it didn't come up when I was searching the internet for a kit.
    Heres a few pics of mine. Not sure on the history of the XXX Pack, I do know the original moulds were destroyed in the fire, but I have a set now.....just in case.




  39. #597
    Pit Crew Decade Plus User

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by 4parajon View Post
    Heres a few pics of mine. Not sure on the history of the XXX Pack, I do know the original moulds were destroyed in the fire, but I have a set now.....just in case.



    Jon Get some moulds made mate.

    What a great build this is Just love the fabrication.

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  41. #598
    Spanner Monkey genRS2000's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by Matt75 View Post
    Great stuff. Why not the group 5 spoiler?

    Cheers

    Matt

    If this is the one you mean, it is a bit over the top for what I wanted.



    Quote Originally Posted by 4parajon View Post
    Heres a few pics of mine. Not sure on the history of the XXX Pack, I do know the original moulds were destroyed in the fire, but I have a set now.....just in case.



    That is wide. I don't think it would fit on my trailer. As it is some of my mates are sceptical mine will fit now.



    To fill in the end gaps I put some masking tape over each end and put filler onto the inside up against the tape.





    Some fibreglass was added for strength.



    Then the tape was removed and more filler was added and this sanded down to give the right profile.







    Primed ready to be painted satin black.


  42. #599
    Spanner Monkey genRS2000's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    Time for some painting.

    Panels in my makeshift spray booth primed.





    Painted Ford frozen white.





    The front inner wheel arches also had a spruce up with POR 15 including the section that I had cut away.


  43. #600
    Spanner Monkey genRS2000's Avatar

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    Re: My New Project ( Millington Escort) to stop me using this

    One thing was very obvious when I put the newly painted arches on the car. The new paint made the old paint looked old and tired so the only thing to do was to repaint the entire car.

    I wasn't too unhappy about this because I was never very pleased with the original job (I didn't do it) so I would be able to rectify this. Also I had always wanted to have the stripes on the roof as well as the sides. This had been impossible because when I measured the sides to have the vinyl stripes put on the datum point I chose on each side (the front of each arch) was not of an equal length from the rear of the doors. This meant that the roof stripe would meet up with only one side, the other being 20mm out.
    I also chose to paint the stripes this time because the vinyl stripes were not very good.


    The grey primer area is were when the stripes were removed the paint also came off, even after heating them. I said I wasn't pleased were the paint job





    I did the stripes first and then the white. All this required a lot of masking and re-masking.










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