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

  1. #601
    Spanner Monkey genRS2000's Avatar

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

    The front has been painted satin black. Apart from the section behind the grille all this will be covered by the added panels.



    Now that everything is finished it is time to put it all together.

    While I am doing that the diff CWP will be getting changed. With the bigger wheels the current ratio (4.6) will be too high. I have done some calculations or rather a programme on a website has, to work out what ratio to use.

    With the current ratio:


    Changing to a 5.3 gives the same as with the 4.6. This is still a bit too high.



    Ideally a 5.5 would be best but it is not available so I have chosen to go radical with a 5.8.


    The 5.8 has 7 teeth on the pinion whereas the 5.3 has 8. This means that the contact area is less and there could be an issue with it breaking. I will find out

    The person changing the CWP wanted a axle housing spreader so I have made one.


  2. #602
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    Re: My new Project to stop me using this

    Quote Originally Posted by jcccruz View Post
    One of the best projects in turbosport
    Agree...

  3. #603
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    Re: My new Project to stop me using this

    Quote Originally Posted by skmotorsport View Post
    Agree...
    Thanks for that. I am just a man in a shed trying my best to create something I can be proud of.


    I have been distracted by other things for a while but I am now back on track.

    I have painted and mounted the rear spoiler.





    Here you can see Version 2.0 of the rear mesh. I have made some plates for the mesh that bolt on so that I can make a change if I want to.


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

    Now that I have a lathe I have been replacing rectangular components I had made previously with round ones.

    The original bonnet buffers:



    new ones:



    To fit them I had to make a special tool because my normal 10mm tools would not fit onto the nut as there is a lip the bonnet flange:



    I found these rubber parts in my stores and they were perfect with a flat ground on one side. Took me a while to figure out what there are: Escort rear spring hanger chassis bushes.



    The rectangular spacers for the bonnet retainers have also been replaced.



    To compensate for the extra weight I have added I have been drilling holes.

    The Watt's linkage mount:



    Bolts centre drilled: probably insignificant but the events I do can be won or lost by 0.0001sec.


  5. #605
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    Re: My New Project ( Millington Escort) to stop me using this

    Today I finished mounting all the bodywork.

    The front spoiler is attached with 1/4 turn camlocs and 6mm ally bolts on the ends. I have to use the bolts because there is not enough flex to get the spoiler in position with camlocs on the end. There are tek screw seals on the bolts to keep them captive when the spoiler is removed so that the bolts don't go missing.





    The support brackets locked into the blocks on the spoiler.



    I have stolen an idea from another Turbosport project to reduce weight. I took a photo of a headlight, scanned it and resized it to the correct dimensions , then printed it on photo paper. This was then glued onto an ally plate and attached to the grill. Clear tape over the photo finished it off. Fooled one of my mates completely





    The new look:




  6. #606
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    Re: My New Project ( Millington Escort) to stop me using this

    Love the headlight idea. Think I might steal that one too!

    Shaun

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

    Quote Originally Posted by escortinadriver View Post
    Love the headlight idea. Think I might steal that one too!

    Shaun
    The person I stole it from probably stole it from someone else




    More weight saving.

    When made the door trims I used some aluminium that I had lying around. This was 1.5mm and now I reckon they are much too heavy so I wanted to replace them with 0.5mm.

    The only problem was that the door closing handles were located on the trim and because I had gutted the doors there would be nothing behind the thinner trims to attach the handles to. Putting the handle on the trim now would mean that the trim would be destroyed.





    My solution also eliminated the door handles.

    I cut a section out of the original trim and bent some angles on each side to strengthen it. The reason for the curved part at the top will be revealed later.






    I didn't have a tool to create the swaged holes so I made one.







    So now the trim is three sections



    and there is a hole to act as a handle.





    I also replaced the rear trims with 0.5mm. I weighed one of the original rear trims and it was 700g, a new one is 220g.

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

    Axle is back in with a new coat of paint.




    Set up for a wheel alignment.



    I have reduced the front camber from 3.5 to 2 and increased the castor to 6.





    A milestone.

    After 6 months on the hoist the car came of it today

    I still a few minor things to sort out and that will be it ( I hope ).

    I am going to take some photos at an outdoor location later this week and I will post them on here.

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

    Here it is.










    and a video




    This is the last time it will look pristine because it is built to be used in competition and I know from previous experience it will not take long to look a little abused

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

    Car looks great.

    Well done.

    Did you weight it before and after?

    Shaun

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

    The before weight was 870kg.

    I haven't weighed it again, it must be more than that now. I need to make lighter arches.

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

    Nice build ��

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

    very nice car

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

    What a job, What a lot of work and you just be chuffed

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

    Thanks those positive comments. I am definitely "chuffed"with the car


    Time for a report of what has been happening in the last few months.

    Since the make over I have competed in 6 events. 2 circuit sprints, 3 point to point sprints and a sprint on a tarmac rally stage.

    The circuit sprint results were 15th and 18th (2 different tracks). These tracks are quite fast and favour modern high power and aerodynamic cars but I have never done very well on circuits for some reason.

    I have done much better on the others: 9th, 5th,6th and 2nd.The courses were much tighter which I prefer as it suits the car.

    With the larger diam/wider tyres the grip level is fantastic now and the 5.8 diff ratio has been a great success... and it hasn't broken yet.

    I now have a video data logger which I used for the point to point sprint last week. I am still experimenting with it. Here are 2 videos from that event:






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  18. #616
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    Re: My New Project ( Millington Escort) to stop me using this

    Very nice mate, great to see you getting soo much use out if it!

    I'm very jealous

    Cheers

    Matt

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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, great to see you getting soo much use out if it!

    I'm very jealous

    Cheers

    Matt
    Next event is in 2 weeks...can't wait

    You are not the only one who is jealous...there is a long line of people who want to have a drive.


    I forgot to mention in the last post that I now have an alternative gear section method.

    This is because I have had problems when doing the point to point sprints as in the video in the last post.Tthere are a lot of tight turns and the paddles are not ideal. The paddles move with the steering wheel which means that when applying lock on a tight turn the paddle positions are reversed which as led me to me selecting the wrong gear in the heat of the moment. I have also accidentally knocked the down paddle in the middle of a hairpin, going from 1st to 2nd. All this has lost me time and a couple of places in the results.

    The solution: buttons on the steering wheel in place of the paddles.

    The switches fit neatly into the wheel with a suitable insert ...the lathe coming handy again.





    Coloured dots to make it easier to see which is which when a quick shift is required.





    This has been a great success. I didn't have any problems in the last point to point and even managed to go down a gear mid spin when I was regaining control of the car in the "off" in the second video.

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

    I have done two events since the last post.

    A wetish (unusual in this part of the world , the last wet event I did was two years ago) circuit sprint and another point to point sprint.

    Video from the circuit sprint:




    The point to point sprint was very difficult because the power steering failed The low power circuit kept blowing it's fuse.

    I have gone back to using my Gopro for the video because I am not happy with the video quality of the video logger....I didn't do enough research before I bought it.

    I came across an application called RaceRender that I have used to overlay information on the video. I am using the data from the logger to do this. It is very good although you have to manually synchronise the data from the logger with the Gopro video.



  21. #619
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    Re: My New Project ( Millington Escort) to stop me using this

    Sod's Law:crazy

    When I looked for the cause of the power steering fuse blowing the system was working perfectly. The only thing I can think of is that I disturbed the controller wires when I reinstalled the Gopro remote On/Off switch.

    So because I could not find the fault I have replaced the controller just it is the problem. I also wanted to replace the Corsa ECU so I searched the internet for a second hand unit but could not find one.
    A few days later this popped up when I was searching Ebay for something else:









  22. #620
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    Re: My New Project ( Millington Escort) to stop me using this

    Sod's Law

    When I looked for the cause of the power steering fuse blowing the system was working perfectly. The only thing I can think of is that I disturbed the controller wires when I reinstalled the Gopro remote On/Off switch.

    So because I could not find the fault I have replaced the controller just in case it is the problem. I also wanted to replace the Corsa ECU so I searched the internet for a second hand unit but could not find one.
    A few days later this popped up when I was searching Ebay for something else:



    a NOS ECU that was in Cyprus! I ordered it and it arrived today so I will fit it tomorrow.


    When I was checking the steering I heard clonking noises coming from the rack. I got a friend to move the steering back and forth while I looked at the rack and was shocked to see the the rack was moving on the mounts. The mount bolts were a bit loose but after tightening them there was still some movement .

    This was interesting because just before seeing this I was looking at the GRP4 Fabrications website and noticed that they sell a plate to give extra strength for the rack mounting.
    So I have made and installed my own.



    This didn't all go to plan though. I made 2 threaded boss's and welded them to the crossmember but when I tightened one of the bolts it locked up about halfway in and would not move in or out
    So I have welded the bolt to the plate and will sort it out in the future when the rack is removed.

    I have a point to point sprint this weekend and another one the following weekend so I hope the power steering is working.

  23. #621
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    Re: My New Project ( Millington Escort) to stop me using this

    Quote Originally Posted by genRS2000 View Post
    Sod's Law
    I made 2 threaded boss's and welded them to the crossmember but when I tightened one of the bolts it locked up about halfway in and would not move in or out
    If ever I weld something with a thread in it I always run a tap through it afterwards, just to clean out any distortion in it...

  24. #622
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    Re: My New Project ( Millington Escort) to stop me using this

    "When I looked for the cause of the power steering fuse blowing the system was working perfectly. The only thing I can think of is that I disturbed the controller wires when I reinstalled the Gopro remote On/Off switch.

    So because I could not find the fault I have replaced the controller just in case it is the problem. I also wanted to replace the Corsa ECU so I searched the internet for a second hand unit but could not find one.
    A few days later this popped up when I was searching Ebay for something else:"



    Something I would suggest to you is that electric power steering units will often have a sensor on them to determine when they are at the end of the rack, so that the electric PS doesnt try to push against the lock stop.

    Often when putting an elec PS system in a car that is not the original application, this is missed, and what happens is when you hold the power steering against the lock stop, with the PS running you will blow the fuse.

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