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Thread: Mk2 Duratec Escort

  1. #361
    Spanner Monkey

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by rallyrob View Post
    Whilst browsing, I really like your reservoir bracket. How much to make me one please?
    Sorry I can't seem to get the photo up.
    Apologies for the slow reply, i have not been on here much recently. Drop me a PM and i can sort you a price for a bracket.

    I will do a proper update on the car in the next few weeks but in brief things have moved on quite a bit. It will be out doing single venue rallies in the next 2 months.

    ​enquiries@flintec-eng.co.uk

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  3. #362
    Spanner Monkey

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    Re: Mk2 Duratec Escort

    Its has nearly been 2 and a half years since this thread had an update, until the beginning of this year there has not been a great deal worth talking about. I had known since the engine first started (which is 4 years ago now) that is would benefit from a mapping session. The car had always started and ran faultlessly on the base map provided by SBD but i knew there was probably room for refinement. Early last year i decided to install a flat shift system then kill 2 birds with one stone at the mapping session. The system i went for is a closed loop system that incorporates the gearbox barrel potentiometer and a micro switch built into the gear knob. Because of the extra height in the gear lever now, the standard Quaife neutral/reverse pin release was a nightmare to reach and use so i have grafted a push bike v-brake lever on in its place, it works great and is easier to us than the standard set up.



    Mapping was done at Motoscope. Turns out the fueling was wayyyyyyy out at lower RPM's. The flatshift system was easy to set up and refine. 222hp was the result of 3 hours on the rollers. The car is way more responsive as a result.



    Treat the old girl to some carbon, also now have front and rear bumpers

    Made a load of slide latches in stainless steel, if anyone needs any, shout up!

    On this that had been annoying the life out of me since the car has been running is watts towers being on the wrong sides to suit my engine. The shell was originally fabricated to suit a NA Cosworth engine, near side exhaust, and the Duratec is a offside exhaust. The issue this caused was near no clearance between the watts bar and the underside of the exhaust. Without chopping them off and re-welding them on, which at the moment is a step to far, the easiest solution for me was to fabricate a cranked bar, which can be seen in red, the standard bar is the gold one. This has bought me a good amount of clearance now and stopped the exhaust contacting the bar on big suspension compression.



    Fitted sill tube to the car and made some custom stands for them



    At the beginning of this year I finally decided to get my finger out and go rallying. It was a big commitment from me both financially and from a work prospective bit it needed doing. The list of things to complete and purchase was huge but 3 months of work saw it get an MSA logbook. At a similar time I completed my BARS test then the next logical step was to get an entry in for an event. DCC stages at Ingleston, Edinburgh was selected. There is not a great deal of single venue stuff on around Yorkshire at this time of year so we decided to load up and head north of the border. This was the first rally for both me and co driver so we were understandably nervous. As a pair of complete novices and seeded car 57 of 85 we had no idea how competitive we would be so it was agreed that we would perform no heroics on the first stage and just get comfortable with car and notes..... that went out of the window on the first corner and we attacked it at 100% Stage 1 was understandably a bit rusty on the communication front but the amount we learnt on the first lap of the first stage huge. It was the first time i have drive the car on slicks and the amount of grip available was mind blowing. Running 13" wheels the choice of tyre supplier is now very limited, i had stocked up on Pirelli Corsa's, the weather was not warm by any means and we had chosen to go on the D7 soft compound. At the end of the first stage we knew where improvements needed to be made from both sides of the car and we were lying 35th. After tghe first 2 stages the soft tyres were completed shot! Pace was increasing stage on stage and after stage 3 we were setting top 20 times consistently. The car operated faultlessly. I was lucky to get away with a high speed spin under braking on a fast right hander on stage 7, at the end of the corner was a tight 90 right around a bale and the D5 hard tyres had completely shot on the back, with the back locking under braking all i could do would set the car up sideways in the direction that we needed to go and wait for it to stop!

    I was more nervous going into the final stage than i had been going into the first. A couple of borks from the engine after the jump did not help the nerves but we kept pressing on. I think/hope this was down to dragging air into the fuel lines.

    We finished the event joint 17th on time and 5th in class which we were over the moon with. Had 3 very experienced guys servicing for us and mentoring all day. They have complied a 2 page list of thing that need sorting before the next event so I am currently on with working my way through all of those.











    Managed to destroy all of these Pirellis



    Had to buy a pair of Hoosiers for the back to get us through those last 2 stages. Seemed to work and last as well at the Pirellis



    First big change to the car is to do away with the pedal box, changing the throttle cable was a hugely complicated and difficult thing to do. It would be the type of thing that could end a rally for us. Also going for a floor mounted one allows me to move my seat further back and get my weight distributed better within the car.



    I will strive to keep this thread active during the upgrades. The next outing will hopefully be June/July time. That should give me time to refine everything a little bit more.

    ​enquiries@flintec-eng.co.uk

  4. #363

    Re: Mk2 Duratec Escort

    Great result well done on that event

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  6. #364
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    Re: Mk2 Duratec Escort

    good to see some updates on this car, well done for having the nerve to rally it

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  8. #365
    I support TS Turbosport Subscriber rallyrob's Avatar

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    Re: Mk2 Duratec Escort

    Well done, good result.. The car looks great out on the stages

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  10. #366
    Spanner Monkey

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    Re: Mk2 Duratec Escort

    Thanks lads.
    I'm am getting stuck into the upgrades now. The pedal box is turning into a much bigger project than it could have been! Going fo a floor mounted pedal box means i can mover the drivers seat as far back as possible in the car. I am a tall bloke and I am still able to move backwards by 100mm before the back of my seat touches the cage,this is all benefiting for better weight distribution but creates a load more headaches!

    Firstly, seat mounts. The rails are too far forwards so i am making a few changes here. Also the wing on the seat is now touching the door bar of the cage so i am making some special seat mount brackets to offset the seat more into the middle of the car, allowing me to move it further back.

    Secondly, Steering wheel position. This also needs to come back, and be removable to allow easier access in and out of the car. I am also looking at moving the power steering motor to down behind the pedal box onto the back of the bulkhead, this will tidy everything up and give more clearance for my knees, and again it is a big heavy component that will benefit weight distribution from being lower in the car. Its looking like i will need to fabricate a bespoke steering column is going to be the best way to go.



    Thirdly. Reach! This is going to be the biggest drama, and its a good excuse for me to attack the wiring. With moving everything back it is now going to be impossible to safely reach any of the switches within the car. The plan is to to so a semi rewire and install one of the new power distribution systems that the professional builders use. These are solid state programmable units that do away with the need for separate fuses/switches/relays and as a result saving a lot of wiring.

    I have made a mount for the pedal box that has a tapped plate welded to the underside, this allows me adjustment in 20mm increments



    It is nearly fitting the car now, another half hour with the grinder and it will be ready to weld in



    The next step is getting the PAS motor mounted, it it will, behind the pedal box

    ​enquiries@flintec-eng.co.uk

  11. #367
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    Re: Mk2 Duratec Escort

    smashing build that, quality oozing out of it, not sure about the light pod tho great car.
    EVERY DAY,S A LEARNING DAY

  12. #368
    Racer

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    Re: Mk2 Duratec Escort

    Good event that, done it myself a few times years ago.

  13. #369
    Mechanic

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    Re: Mk2 Duratec Escort

    Class, keep the updates coming.

  14. #370
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    Re: Mk2 Duratec Escort

    I want floor mounted box can't wait to see the finish

  15. #371
    Spanner Monkey

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by twoRSs View Post
    I want floor mounted box can't wait to see the finish
    It is fully installed now, i will get you some photos over the weekend. I am a little over 6 foot tall and am sat as far back as possible, the pedal box is as far forward as possible, i would recommend getting the pedal box with the master cylinders mounted on the front of the assembly, under your heals rather than the type i have with the cylinders on the back, especially if you are tall. It will give you chance to adjust your driving position.

    Since the last update we competed on the JRT Enville Stages at Anglesey. Seeded 43rd we were off to a fairly decent start, just outside of the top 20, the car took a few stages to get the hang of again with the new steering/pedal box set up. A BIG BIG spin on stage 3 cost us around 15 seconds but we were on the edge of the top 20 by the end of stage. Stage 4 was the end though, a broken toggle switch on the first loop of stage 5 ground us to a stop, we managed another lap with me holding the switch and Josh pulling the gears but if completely failed on the second to last corner.

    The car is undergoing change again now, i am busy doing a motorsport spec loom for the car and installing a Cartek power distribution module to look after all of the electrical circuits. I am also making some changes to other bits an pieces in the car, i will update this as i go.

    ​enquiries@flintec-eng.co.uk

  16. #372
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    Re: Mk2 Duratec Escort

    Great work as always mate

    I'm using the EZ Wire loom too. Just curious as to why you are removing it?

    Cheers


    Matt

  17. #373
    Spanner Monkey

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by Matt75 View Post
    Great work as always mate

    I'm using the EZ Wire loom too. Just curious as to why you are removing it?

    Cheers


    Matt
    The loom continuously evolved Matt, if i had know from the start what i was going to add years down the line the EZ loom would have been fine. I have ended up with multiple bits of loom running to the same parts of the car which is a bit messy and would be very difficult to fault find on, especially now we are using the car competitively. The failure on the last event was a switch, which was just unlucky, to eliminate the complication of fuses, switches and relay and the extra wiring that interfaces between them i have decided to use a PDM (power distribution module) that can be programmed to serve any circuit. This will make the wiring simpler, lighter and remove many points of potential failure.

    I have fabricated this box to mount the PDM in, it fits nicely between the seats.



    This is the start of the rear harness for the boot








    ​enquiries@flintec-eng.co.uk

  18. #374
    Mechanic Matt75's Avatar

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    Re: Mk2 Duratec Escort

    Very nice mate. Looks like a great bit of kit.

    I went for the EZ Wire 21 circuit kit to allow for future upgrades.

    Your attention to detail is great to see. Keep up the great work

    Cheers

    Matt

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  20. #375
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    Re: Mk2 Duratec Escort

    I just came across this thread and must say you are an excellent craftsman, I cant help love the retro look of the cam cover and it will fit right in with my project, are you making these available for sale?

    Thanks, Rob

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