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Thread: Mk2 Duratec Escort

  1. #41
    Spanner Monkey

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    Re: Mk2 Duratec Escort


    Engine and box ready for first fitting

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  2. #42
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    Cracking work mate
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
    1972 MK3 Cortina 1600XL
    1984 Sierra XR4i
    And other junk I don't like to talk about!

  3. #43
    Spanner Monkey johnaboyy's Avatar

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    Re: Mk2 Duratec Escort

    That will look the dog's danglie's under the bonnet!!!!

  4. #44
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    Re: Mk2 Duratec Escort

    Big thanks to Paul for calling in last night and motivating me to get the engine in. Got it dropped in and roughly in place last night before beers. spent all of today measuring and adjusting the position, measuring again, cutting, jacking and more measuring. Finally happy with the position. re fitted the steering column and trial fitted the manifold which is fouling the existing chasis engine mount on the o/s. going to have to cut it off tomorrow and reloate it around 80mm further forward to clear the lower part of the manifold. once thats moved i can get some mounts fabricated

    Click image for larger version Name:	IMG_0902.jpg Views:	37 Size:	229.4 KB ID:	47787

    Click image for larger version Name:	IMG_0909.jpg Views:	35 Size:	143.6 KB ID:	47788

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  5. #45
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    Re: Mk2 Duratec Escort

    Got the offending bracket removed this morning and the manifold fitted. engine and gearbox mounts next
    Click image for larger version Name:	IMG_0912.jpg Views:	34 Size:	221.4 KB ID:	47806

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  6. #46
    Spanner Monkey johnaboyy's Avatar

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    Re: Mk2 Duratec Escort

    Bet your glad the manifold is on!!. Keep up the good work, cant wait to see more progress.

  7. #47
    World Champion Decade Plus User cossymax's Avatar

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    Re: Mk2 Duratec Escort

    Nice tidy install, and cracking car


    Old skool forever
    Just don`t tell the wife
    how much it really costs!

  8. #48
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
    1972 MK3 Cortina 1600XL
    1984 Sierra XR4i
    And other junk I don't like to talk about!

  9. #49
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Cracking job bud I'll be starting mine in the winter.

  10. #50
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    Re: Mk2 Duratec Escort

    Thanks for comments guys. Started on the engine mounts last night and this was what i had in mind

    Click image for larger version Name:	EngineMountExample.jpg Views:	34 Size:	22.1 KB ID:	47960

    the plan is to use 15mm round bar to create 4 spurs, then to box them in using 2mm sheet. this will be so much easier than cutting large tube to suit the geometry........ and i think it looks much nicer

    Quote Originally Posted by trig View Post
    Cracking job bud I'll be starting mine in the winter.
    thanks trig, have you made a final choice on what motor your using?

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  11. #51
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    Re: Mk2 Duratec Escort

    Made these screw jacks at work to aid the positioning and leveling of the engine before welding the mounts up

    Click image for larger version Name:	IMG_0917.jpg Views:	37 Size:	194.8 KB ID:	47975

    This is as far as we got last night with the mounts. 2 spurs on each side. going to get the engine out next and finish them off on the bench

    Click image for larger version Name:	IMG_0915.jpg Views:	34 Size:	208.8 KB ID:	47976

    ................and whilst i had my welder working on the car got him got float over the cage welds with the tig to tidy them up

    Click image for larger version Name:	IMG_0916.jpg Views:	33 Size:	206.3 KB ID:	47977

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  12. #52
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    Re: Mk2 Duratec Escort

    Wiring loom has arrived from the states. its made by a company called Kwik Wire and are mainly used in the hot rod scene. The loom has the following 14 circuits

    Brake Lights
    Radio Constant
    Horn
    Headlights
    Dome Light
    Fuel Pump
    Radio
    Gauges
    Wipers
    A/C and Heat
    Hazard Light
    Back up lights
    Electric Fan
    Coil
    Turn Signal

    Some of these will be swaped for other uses. Each wire is printed up with its use and the loom is seperated into various groups to aid installation

    Click image for larger version Name:	IMG_0921.jpg Views:	34 Size:	275.6 KB ID:	48069

    Click image for larger version Name:	IMG_0922.jpg Views:	30 Size:	197.5 KB ID:	48070

    Fabricated a bracket from stainless to mount the fuse board vertically on the gearbox tunnel

    Click image for larger version Name:	IMG_0919.jpg Views:	27 Size:	119.3 KB ID:	48071

    Click image for larger version Name:	IMG_0920.jpg Views:	30 Size:	188.7 KB ID:	48072

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  13. #53
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    Re: Mk2 Duratec Escort

    Designed a bracket for the clutch and brake reservoirs as i cant find an off the shelf one i like the look of. Plan is to fit it on top to the bulkhead on the n/s

    Click image for larger version Name:	CylinderResevoirLayout.jpg Views:	27 Size:	34.4 KB ID:	48079

    Designed it on Solidworks from rough measurements. this allows me to print out a flat pattern of the part. with a bit of cutting and sellotaping came up with this blue peter special to test the fit

    Click image for larger version Name:	IMG_0914-1.jpg Views:	26 Size:	112.3 KB ID:	48080

    After trying it this afternoon a few of the dimensions do need changing to get the fit spot on. will have another go tomorrow then get it sent off to the laser cutters for manufacture

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  14. #54
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    Re: Mk2 Duratec Escort

    Had a bit of a shuffle about in the workshop to get another car in
    Click image for larger version Name:	IMG_0923.JPG Views:	31 Size:	1.26 MB ID:	48123

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  15. #55
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    Re: Mk2 Duratec Escort

    Been working away most of this week so had very little chance to get anything done

    Engine mounts are nearly finished though, just need gusseting
    Click image for larger version Name:	IMG_0929.jpg Views:	44 Size:	171.2 KB ID:	48225

    Click image for larger version Name:	IMG_0930.jpg Views:	44 Size:	222.9 KB ID:	48226

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  16. #56
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    Tidy welding
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
    1972 MK3 Cortina 1600XL
    1984 Sierra XR4i
    And other junk I don't like to talk about!

  17. #57
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    Been working away most of this week so had very little chance to get anything done

    Engine mounts are nearly finished though, just need gusseting
    Attachment 48225

    Attachment 48226
    Liking these engine mounts.Look like the ones RetroFord made for his MK2 escort drag car

  18. #58
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    Re: Mk2 Duratec Escort

    Found some pictures of the retroford ones, going to have to change the way im gussetting mine to keep them different
    Im afraid i cant take credit for that welding, a guy from work has done it for me.. he builds his own choppers in his spare time. all his work is second to none. will get some pictures of a few bikes

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  19. #59
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Looking good bud got all this stuff to do on mine so watching closely.

    Ive started A thread now too.

  20. #60
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by trig View Post
    Looking good bud got all this stuff to do on mine so watching closely.

    Ive started A thread now too.
    Cheers Trig, i have been having a look at your build. loving moving the motor right back, ignore the haters. it will be a weapon when its done

    Bit of a digression, here are a could of bikes that my welder has in his collection
    Click image for larger version Name:	IMG_0932.jpg Views:	28 Size:	173.3 KB ID:	48316
    Current bike he built with 1964 Harley Sportster engine (For Sale)

    Click image for larger version Name:	IMG_0933.jpg Views:	23 Size:	154.1 KB ID:	48317
    Current work in progress, Custom with 750 twin motor

    ..........Back to the escort

    Degined a tunnel extension to weld on which should be ready by the weekend. had been struggling to find a sensible gear gaiter. finally opted for a fiesta mk6 item and got one cheap off ebay
    Click image for larger version Name:	IMG_0935.jpg Views:	26 Size:	181.0 KB ID:	48318
    Will have to make an insert to go in the top and some kind of plate to tie it down to the tunnel.

    Also ordered some Powerflex universal bushed to crate a gearbox mount. Not really got a plan for it yet so hoping that getting some parts together will give me some inspiration.

    Finally ordered a new waterpump for the motor, the origional one was not looking in brilliant condition. Was nearly tempted to go down the route of an electric pump which most of the duratec installs seem to use, but going to stick with the mechanically driven one and keep it simple.

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  21. #61
    TURBOSPORT SPONSOR Turbosport Sponsor brafferton's Avatar

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    Finally got some photos of the tunnel







    Tank platform welded in and carbon fibre spare wheel tray trimmed to fit


    Boot catches in place with some 3M carbon fibre trims


    ..........this was a bit of an experiment!happy with how it has panned out so it can stay! was a bit concerned about how ealisy the sliders opened on the front windows so got hold of some m5 spring loaded plungers from a work supplier and made some plates to mount them in....drilled the bottom of the slider at 25mm increments, this allows 10 positions for the windows to be positivly held at
    Im the guy that made your polycarb windows. Like the look of the locking system you made. Hope you dont mind if I pop next door and have a look.
    Stuart.
    Airedale Race Components
    01423 360456
    http://www.raceplastics.com

  22. #62
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    Re: Mk2 Duratec Escort

    Hi Stuart. Was hoping to bump into you at some point. Firstly, thank you for sorting me out with the rest of the windows. Top job. Feel free to pop around have a look whenever you like. Im up there some evenings and most weekends. The window catch plates work really well, they are only a prototype at the moment though. I have the finished parts drawn up, just need to get them onto the laser cutter. They are a smaller shape with nice radii on the corners.

    They will look like this

    Click image for larger version Name:	window catch.JPG Views:	31 Size:	84.7 KB ID:	48373

    I have PM'd you my contact number

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  23. #63
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    Re: Mk2 Duratec Escort

    Made an aluminium insert for the top of the fiesta gear gaiter this morning. Still undecided about the bottom yet, will need to wait until i get the tunel extension made at the weekend

    Click image for larger version Name:	IMG_0941.jpg Views:	24 Size:	233.7 KB ID:	48374

    Click image for larger version Name:	IMG_0942.jpg Views:	25 Size:	229.8 KB ID:	48375

    Also got 2 pairs of the Powerfox bushes for the gearbox mount

    Click image for larger version Name:	IMG_0940.jpg Views:	22 Size:	144.3 KB ID:	48376

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  24. #64
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    Re: Mk2 Duratec Escort

    Made some good progress tonight after a trip to collect some parts today.

    Gearbox tunnel extension and brake/clutch cylinder reservoir bracket
    Click image for larger version Name:	IMG_0943.jpg Views:	44 Size:	150.3 KB ID:	48401

    Gusset plates for the under side of the A pillars
    Click image for larger version Name:	IMG_0944.jpg Views:	26 Size:	153.9 KB ID:	48402

    Gussets to finish off the engine mounts
    Click image for larger version Name:	IMG_0945.jpg Views:	22 Size:	145.4 KB ID:	48403

    Still not quite worked out what im doing with the gearbox mount, made some stainless housings for the bushes to get me one step closer to a solution
    Click image for larger version Name:	IMG_0946.jpg Views:	23 Size:	143.6 KB ID:	48404

    Went to the lock up to check the fit of all the parts. By chance had works capasitor discharge stud welder in the van so used it to get the mountings on for the reservior bracket and a few earth points around the car. Worked a dream, they are impossible to neck off when applied right.
    Click image for larger version Name:	IMG_0947.jpg Views:	25 Size:	251.1 KB ID:	48405

    Click image for larger version Name:	IMG_0948.jpg Views:	21 Size:	193.2 KB ID:	48406

    Click image for larger version Name:	IMG_0951.jpg Views:	24 Size:	170.0 KB ID:	48407

    Finally........ got all the rollcage plates trimmed and stuck into position ready for welding next week. (The ratchet strap is the current gearbox mount!!!)
    Click image for larger version Name:	IMG_0952.jpg Views:	25 Size:	233.4 KB ID:	48408

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  25. #65
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    Looking really good there, I love that stud welder too
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
    1972 MK3 Cortina 1600XL
    1984 Sierra XR4i
    And other junk I don't like to talk about!

  26. #66
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by exboyracer View Post
    Looking really good there, I love that stud welder too
    Thanks it really is a neat way of fastening things down. No more fiddling around up the back of panels trying to find nuts

    been working away in east yorkshire all weekend and got a bit of a flier today so called in unannounced to Ralloy on the way home to get a strut brace and some window seals.

    Click image for larger version Name:	IMG_0961.jpg Views:	29 Size:	183.9 KB ID:	48530
    They had non of these alloystrut braces made when i arrived but by the time i had got settled up Roy had welded one for me. Top quality and top service all round

    Whilst there i spotted a batch of these on the shelf and had to get one.....
    Click image for larger version Name:	IMG_0960.jpg Views:	25 Size:	186.1 KB ID:	48531

    Buy the looks of things, the normal way to mount these is on a mild steel base which is welded into the boot floor......... but i think i will just break out the stud welder again

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  27. #67
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    Re: Mk2 Duratec Escort

    Quick update, machined the tunnel extension out to take the gear gaiter tonight. Test ftted it and it looks good. Had to put getting the welding off for another week due to work commitments but its giving me chance to get a few more bits organised.

    Click image for larger version Name:	IMG_0964.jpg Views:	21 Size:	148.5 KB ID:	48569

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    Re: Mk2 Duratec Escort

    Some lovely looking bits there bud

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    Re: Mk2 Duratec Escort

    Cheers Trig. Had a lack of updates due to loss of my iphone for taking pictures. Got myself a new iphone 4s at beginning of the week! Already smashed the ba***rd! its still a runner though so managed to get a few pictures.

    Got a remote oil filter housing, wont say where from as its not there there fault but the quality of it was crap to be fair. Its a Mocal one, for a 3/4"UNF filter, 1/2"Bsp fittings. Sharp edges and flash from themanufacturing and saw marks where it has been cut off from the cast. after about an hour attaching it with files and emery paper got it loking half nice.

    Banged a couple of studs onto the n/s inner wing to mount it. think i will get it powdercoated to finish it off

    Click image for larger version Name:	IMG_0973.JPG Views:	25 Size:	1.73 MB ID:	48722

    Stud elded into the boot to mount the dry sump tank too. this sat on 2 different levels so have got one side on some ally spacers

    Click image for larger version Name:	IMG_0974.JPG Views:	28 Size:	1.82 MB ID:	48723

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    Re: Mk2 Duratec Escort

    Click image for larger version Name:	IMG_0997.JPG Views:	21 Size:	3.24 MB ID:	48760

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    Re: Mk2 Duratec Escort

    Fabrication of the engine mounts completed today. Thrown a bit of primer at them, think i will get them powder coated before the final assembly

    Click image for larger version Name:	IMG_1001.JPG Views:	29 Size:	1.96 MB ID:	48795

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  32. #72
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    Tidy!
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
    1972 MK3 Cortina 1600XL
    1984 Sierra XR4i
    And other junk I don't like to talk about!

  33. #73
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    I'm lovin the engine mounts.
    Did you cut your own engine plates?
    Do you think you could cut me some Please???

  34. #74
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    Re: Mk2 Duratec Escort

    Great project. Youve set the standard there. Those engine mounts are a work of art.
    RWD Escorts - Making the competition look like c**ts since 1968!

  35. #75
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    Re: Mk2 Duratec Escort

    Thanks for the comments guys. Next step is the gearbox mount then can get the motor back out.



    Quote Originally Posted by trig View Post
    I'm lovin the engine mounts.
    Did you cut your own engine plates?
    Do you think you could cut me some Please???
    I use a company near york for my cutting. use the day in day out through work so they cost next to nothing. when your ready for them get the measured up to suit and give me a shout and i will draw them up and send them off for you.
    got the 8mm engine mount plates drawn up too so if you need a set cutting give me a shout

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  36. #76
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    It's just the engine plates I'm after bud I got a chassis mount from another engine install there's a guy on eBay selling just the plates for £20.

  37. #77
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by trig View Post
    It's just the engine plates I'm after bud I got a chassis mount from another engine install there's a guy on eBay selling just the plates for £20.
    Will get you a price sorted tomorrow when im back in the workshop mate. Will get a few sets cut to keep the price as low possible. Will stick the rest on ebay

    ​enquiries@flintec-eng.co.uk

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  39. #78
    Spanner Monkey

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    Re: Mk2 Duratec Escort

    Another great weekend working on the car. Mainly fabrication

    Lifted the motor and box back out on thursday to free up some room for the weekend work and bolted the engine mounts on
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    Firstly, Had not got around to designing any plates for gearbox mounts. Gave in in the end and just made them up as i went along. The only mild steel material i could find that would be suitable was this piece of rsj! So got busy with the grinder and cut the web out

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    Welded them into the tunnel and they look spot on.
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    Strut brace brackets welded on
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    All the roll cage plate welded in and primed
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    Tunnel extension welded in ready for paint. also studs on to mount the fuse block
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    Chuffed to bits with the progress. really feels like its in motion again

    Need to get the mig welder back out to finish off the o/s chassis engine mount and the eye bolt plates for the harnesses then its ready for paint
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    ​enquiries@flintec-eng.co.uk

  40. #79
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Fair play bud cracking job.

  41. #80
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    Nice work mate
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
    1972 MK3 Cortina 1600XL
    1984 Sierra XR4i
    And other junk I don't like to talk about!

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