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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.


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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.


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    Spanner Monkey genRS2000's Avatar

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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 3.5º to 2º and increased the castor to 6º.





    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

  16. #615
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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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    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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    Spanner Monkey genRS2000's Avatar

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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.



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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.

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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...

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

    very nice build

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

    After seeing a new post on my build thread it reminded me that I should update it.

    I have had no issues with the power steering since replacing the components mentioned in my last post.

    What was causing a problem midway last year was the clutch. It was sticking when it was cold making it very hard to manoeuvre the car around the pits. It was aright when it had warmed up after a few laps.
    It was my intention to take the engine out at the end of last year to have it rebuilt so I wanted to wait until then to replace the clutch but eventually it was impossible to take off so the gearbox came out and the clutch was replaced.

    While it was out I wanted to have the prop shaft unijoints replaced because they get a hard time as the engine sits at a less than ideal angle in the engine bay.
    I took it the the same people who had replaced them before and happened to mention that the prop was now spinning at a greater rpm because I had changed the diff ratio. I was then told that the prop was right on the safe limit and it really needed to be a larger diameter so they made a new one that was 83mm diam rather than 75mm.

    Everything went back together and was fine although there was a different sound being made by the prop shaft which I assumed was because it was larger.

    I did some more events with very good results until the last sprint of the year. At about 9200 rpm ( prop shaft around 10200 rpm) in 6th gear that was a very loud bang and then a very bad vibration.
    Back home with the car on the hoist it was clear that the problem was a missing balance weight on the prop shaft . Also the front yoke was very stiff when it was moved in one plane.

    So I took it back to the manufactures who admitted that the stiffness had been their fault and that it was the cause of the missing weight and it was fixed under warranty.

    I now had to make a decision regarding the engine.

    I have been competing in a sprint and hillclimb series for nearly 20 years which has always had an under 2 litre class but this has recently been changed to under 3 litre. The major race club here has started a new series of sprints, hillclimbs and point to point sprints that I was going to compete in ( postponed as a result of the COID-19 lockdown) that has an under 2.5 litre class.

    So instead of having my 2 litre rebuilt I now have the latest spec Millington Diamond Series 2+ 2.5 litre engine.




    The new engine has Coil On Plug ignition and sequential fuel injection. It also has a slanted intake manifold and a narrower air filter that makes it easier to fit into an Escort engine bay. This meant that I was able to correct the engine angle so now the rear of the engine is canted slightly towards the RHS just like the Twincam Escorts.

    While the engine was out I moved the brake/clutch reservoirs because although it looked good with them in the centre filling them was difficult . The new exhaust manifold has larger diameter pipes and is a 4-2-1 rather than the 4-1 for the old engine when meant that the RHS engine had to be repositioned because the manifold wanted to go where the mount was.

    It took a month to sort all this out and when I tested it on the track two things stood out.

    First the 2.5 litre has a completely different character than the 2 litre.... much more brutal.

    Unfortunately I could only do a few laps. It was a hot day and the oil temperature was getting too high. I was able to get away without having an oil cooler with the 2 litre but it was obvious that the 2.5 litre needed one. I have since found out that this is because the 2.5 has oil squirts on the pistons so the oil is getting hotter.

    I have now installed an oil cooler in the boot with ducting from the rear arches .

    I am now waiting for an opportunity to test this out.

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

    1970 Mk1 Escort Tarmac Rally Car

  29. #626
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    Re: My New Project ( Millington Escort) to stop me using this

    Just found this build thread I look forward to reading it all from the start

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

    I wonder if a 4-2-1 manifold compared to a 4-1 type makes as much difference with a car sized engine as it does with bike engines? With those the hike in the mid range can be significant but with a slight top end loss - can't imagine a Milli 2.5 is going to need much mid range but it all helps!

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

    Quote Originally Posted by katana View Post
    I wonder if a 4-2-1 manifold compared to a 4-1 type makes as much difference with a car sized engine as it does with bike engines? With those the hike in the mid range can be significant but with a slight top end loss - can't imagine a Milli 2.5 is going to need much mid range but it all helps!
    I’ve been reading up on differences on 4-1 vs 4-2-1 on yb’s and many seem to prefer the the 4-2-1

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

    Quote Originally Posted by Cossie55ish View Post
    [I]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.

    This is handy to know, it makes sense really, thanks.

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

    Agreed. Little bit to add is also to keep the orientation of the ECU in the same position as the donor car.
    Got told this recently by a knowledgeable member on this forum.

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

    Quote Originally Posted by dt36 View Post
    Agreed. Little bit to add is also to keep the orientation of the ECU in the same position as the donor car.
    Got told this recently by a knowledgeable member on this forum.
    Hitting the lock stops wasn't my issue but thanks for the info. I doubt my ECU has the same orientation as the original

    Julian Millington watched a video of my car competing in a point to point sprint and concluded that I needed low to mid range torque rather than top end power so he supplied the 4-2-1 exhaust. A 4-1 exhaust is available for the 2.5 litre which would be more of a benefit for a pure race car.

    Here are some photos of the oil cooler installation.



    There is a cooler under the shroud.



    Air is ducted from the rear arches. I need to repaint this section.


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  36. #632
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    Re: My New Project ( Millington Escort) to stop me using this

    There has been quite a bit of activity since my last post...some good, some bad.

    The COVID 19 restrictions were eased here so motorsport was able to resume but with strict conditions. My first event was another point to point sprint at the local racetrack.
    This was my first competition outing with the new engine and things went a bit wrong.

    On the practise run I applied too much power in the final chicane and hit the tyre wall ( arrowed in the photo below) with the left rear corner. My excuse was that I was not used to the extra power with the 2.5 as I could apply full throttle at the same point with the 2litre with no problem.



    The arch was now rubbing on the tyre but after cutting some of it away I was able to do some more runs....being much more careful through the chicane.

    I had always meant to make moulds of the arches just in case something like this happed but I had put it off because it will not be a pleasant job so I had to fix the damaged arch. This had to be done quickly as I had one event 6 days later and another in 14 days.

    It doesn't look pretty.




    Fortunately the front section of the arch was not damaged...it had just come away from the body slightly so I cut the rear section off .



    The I used a jack to get the steel body sections back into line as much as I could.








    I had to use whatever I had to remake the arch because I didn't have time to go out to get things. So I constructed a frame from wood, aluminium and plastic water pipe using the right hand arch as a template.






    I did make a change to the rear of the arch for 2 reasons. Firstly I was never happy with how the rear looked and because it had compound curves I would need to make the mould in 2 pieces.
    Now the rear is more or less square the mould can be made in 1 piece.

    I didn't have time to do any painting so the next event was done with the repair at this stage. It did look lop sided because the RHS was still the original shape.

    I did get time to do the painting



    before the following event ( a super sprint) but for that and the next event ( back to the racetrack for a different point to point) it still had the lop sided look.
    The next job is to modify the RHS rear to be the same as the LHS and then make some moulds.

    Video of the different P2P. We went through the offending chicane the other way and I didn't hit it. I have now become used to the extra power and torque which is as made the car much faster and much more fun to drive especially the standing starts as the extra torque means it will take off using 6000 rpm not 8000 as before.


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

    She definitely took a whack to crease the quarter panel and not destroy the arch - built too strong LOL!

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

    Quote Originally Posted by katana View Post
    She definitely took a whack to crease the quarter panel and not destroy the arch - built too strong LOL!
    It was quite a whack. The main impact was just behind the wheel so it could have been a lot harder to repair if it had been in the middle.

    Video clip of the impact:


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

    Lovely car, really interesting build thread, thanks for taking the time to post.

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

    Quote Originally Posted by genRS2000 View Post
    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.

    Hi, Just be cautious with the 5.8, the small pinion will generate a lot of heat with high HP, Boreham used fit a larger differential cover to increase oil quantity back in the day but this is not possible with the modern watts cover. I am open to correction but they might have also used a diff oil cooler on some events to try dissipate the heat.

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

    I couldn't work out why there was no difference between the 4.6 and the 5.3 ? ? ? Then noticed the tyre diameter had grown by nearly 4 inches? No wonder there was little change! Not sure its healthy running a diff that (5.8) low?

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

    5.8's are used in rallying quite alot with high revving engines.

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

    Quote Originally Posted by Erikmex View Post
    5.8's are used in rallying quite alot with high revving engines.
    Yes correct with high revs but high torque engines on some occasions pose an issue as your contact pattern between the crownwheel & pinion is small.
    Very interesting project

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

    Ive seen alot of guys expermineting with case hardenign when its been an issue, tuftrided gears etc.

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