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Thread: Mk2 Duratec Escort

  1. #81
    Pit Crew Decade Plus User 105Ian's Avatar

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    Re: Mk2 Duratec Escort

    Very impressieve build , and some lovely touches

  2. #82
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Mk2 Duratec Escort

    Some great fabrication there mate, keep up the superb work.

    What spec you hoping to run the engine? Are you keeping the 4-1?

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    Re: Mk2 Duratec Escort

    Thanks for the comments guys.

    Matt, going to build it to Steve B's 245bhp spec. That manifold is a 4-2-1 built to suit 250. 1 3/4" matched primaries, 2 1/2" outlet. still debating whether to put an exhaust tunnel in or to fabricate a special section exhaust , dont like cutting big holes in it!!!!!

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  4. #84
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    Re: Mk2 Duratec Escort

    Very stedy progress over the last week. Was the final round of the British Rallycross at Croft last weelend and we are away to Wales today for the wrc.

    Ordered all the fittings and hoses for plumbing up the dry sump. they should be arriving any time before the weekend. Also made a start wiring the battery isolator and running power cable through the car.

    Borrowed this hydraulic terminal crimper off a mate, saved loads of time and does a perfect crimp
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    Surge protection reistor soldered up. Going to make a clip for this so i can fasten it down to something. The resitor wires fragile and pretty crap tobe fair.
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    The isolator is wired now, main power cable run through a gland in the front bulkhead. then in the other direction, back to a maxi fuse then into the battery box behind the seats. Will get some photos up when i get back after the weekend.

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    Re: Mk2 Duratec Escort

    Big box of fiings arrived today from Torques_uk for plumbing up the oil system. Still waiting on the -12 straights but this will keep me busy for a few nights.

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  6. #86
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    Re: Mk2 Duratec Escort

    The surge protection resistor in one of my last posts broke! The wires snapped off. Found a replacement one with spade terminal base from an online shop so ordered a couple. Braided a harness up for it too.

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    It is still a fairly fragile so machined a small mount for it at work this week. Mounted it onto the side of the fuse board bracket.

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    Made a start running the oil lines, opted to run between the rear quarter and interior. Put bulkhead fittings in the rear so i can eaily remove the tank for oil changes and cleaning.

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    Got a set of carbon door and rear quarter cards coming next week. Cut one of the ali ones and inserted a Naca duct to allow the hoses to pass through. Will use this as a template to cut the carbon one when it arrives.
    Need to machine an insert to put into the duct to support the hoses next

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  7. #87
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    Re: Mk2 Duratec Escort

    Progress has been steady over Christmas due to a lack of funds.......

    Got the carbon fibre door cards fitted using some well nuts.
    Using works rivsert gun put some insets into the doors for attaching some ally door handles which feel nice and solid.

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    Made a start wiring the centre console after much head scratching about what switches and relays i need, im sure i will have missed something........time will tell.

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    Been and bought some relays and relay bases this afternoon. Need to mill a pocket into the centre console tomorrow so i can get them mounted. This is what i have in mind, need to come up with some kind of 90 bracket to fasten everything together.

    Click image for larger version Name:	CentreConsole.jpg Views:	21 Size:	22.7 KB ID:	50574

    Im going to meet Rick of Mk2Mania tomorrow to have a look at his power steering kits, need to make sure i can fit one in between my pedal box and the cage cross member. If i can get the motor in i want to look at adding an extra UJ to the set up to get the steering column squared up to the driving position.

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  8. #88
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Slow and steady bud

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    Re: Mk2 Duratec Escort

    Good progress today.
    After speaking to Rick from Mk2Mania during the week, decided that power steering was achievable. Rather than using the normal single piece steering column which sits at an angle like the standard one, im going to add an aditional shaft and couple of universal joints to square the column up.

    Got a majority of the parts through the week so gave it a trial fitting.

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    Once it was square in place it became apparent how far off the driving centre line the wheel would be. Decided that moving the mounting point to the right to re-centre the wheel position would be the best solution. I planned on fiitting the dash top to be able to identify the ideal position, problem was..........not tried fitting the dash since welding in the roll cage gusset plates!


    The bottom of the plates were too low to allow the dash to drop in. After a bit of head scratching came up with a possible way around it. Cut a piece out of the dash top panel away which then allowed the dash top to drop into place.

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    Once in place I managed to determine the actual and ideal centre line. the difference was 30mm

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    Cut off the old mounting studs and welded in some bolts into the new position

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    Happy with the new position, the botom section of the shaft needed to be located. Using a 2 bolt 20mm flange bearing in the bulkhead meant having to turn up a sleeve to adapt the shaft from 17.5mm to 20mm. Tacked the sleeve onto the shaft to hold it in place

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    Just need to cut back the bottom shaft and fit the central section with the other 2 uj's in. I will leave this until next week, by then i should have sorted out the bracket between the power steering motor and the pedal box to fix its location. There is no clearance between the motor and the right hand master cylinder so i this i will modify the pedale box at some point.

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    Still need to come up with a mounting bracket for the controller, im thinking the best place to mount it will be on the inside of the strut triangulation of the roll cage.

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    Bought one of these thermal transfer label printers which also print onto heat shrink.......

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    Braided and heat shrunk the controller wires up for the power steering ecu

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  10. #90
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Looks great bid where did you get the stearing parts from as I'll need to do some thing like that on mine when the time comes.

  11. #91
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    Re: Mk2 Duratec Escort

    The motor converted with a mk2 top shaft, controller and all the parts for wiring were from Rick at Mk2Mania, top bloke, answered all the questions i had to throw at him, very helpfull. http://www.mk2mania.co.uk/

    The bearing i used was a 20mm self aligning 2 bolt flange bearing with thermoplastic housing. The one i used is from work so was a food safe plastic one! Part number PSFT20CR. There are loads of cast housing ones on the market which are much cheaper. The size of this bearing housing just covers the hole in the bulkhead nicely.

    I made the sleeve for the bottom shaft, which is just a standard escort one. Dimensions were 20 Outside diameter, 17.5 Inside diameter, 35mm Long

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    Re: Mk2 Duratec Escort

    Got the power steering finished off this week. Shortened the bottom section of shaft and machined 3 flats onto it to suit the central section universal joints. Also welded a tapped boss onto one of the UJ's to make it a likke easier to assemble.

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    Completed steering set up.

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    Plan is to run the standard column stalks and to keep it all tidy im going to run the normal steering column surrounds, picked these up a few weeks ago. Fiberglassed up the holes which are not required. Going to send them off to get flocked once i know they fit the column.

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    Been looking at seats for a while, and i have been at a point in the build where i have been needing to decide where to route pipes and wires.
    Had a sit in a standard width Corbeau seat before Christmas and found it far from comfortable for my shape, was too narrow for me. Spoke to a few other lads and tried a Sparco one in a mates rallycross car, again standard width but felt much wider. Decided on a trip to Autosport show with the intention of being able to try out all suppliers and models. Good turn out from all suppliers apart from Sparco shocked that they had no seats on thier stand.

    Ended up finding a few of theirs on other peoples stands and in cars. The one that i fit in best had to be the Pro2000, i found with other makes my shoulders would be in more contact with the seat than my spine.

    Got one ordered anyway and was delivered yesterday

    Plan is to get this one mounted up with the steel mounts for now and then get some ali mounts designed and cut when i have a litle more time one my hands.

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    Tried it for size tonight and the seat bars already in the car are on completly the wrong centres for these mounts

    Will get some steel tomorrow, cut the old ones out and weld in some fresh ones.

    ​enquiries@flintec-eng.co.uk

  13. #93
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    Good work there
    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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    Re: Mk2 Duratec Escort

    wow just read all this top quality project, What do you do for a living obviously a CAD designer of some sort i guess. Love solid works and solid edge use them at uni.
    attention to detail is awesome. I look forward to the updates.
    Fiesta ST.

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    Re: Mk2 Duratec Escort

    Thanks for the comments. I am the designer for a company called Quasar Automation based near Ripon, North Yorkshire. We design and build bespoke automation solutions for the food industry. Our products range from simple conveyors to fully automated robotic lines. Baiscally anything that our customers can not buy off the shelf. I served my apprenticeship in the workshop on the machines and spanners so its put me in good stead for building this ride

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  16. #96
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    Re: Mk2 Duratec Escort

    lookin sweet that mark,,, just shows how off centre the whole set up is i a stock escort ,, the extra time it takes to square it up is worth while when your are sat in the right position and its all lined up straight ( feels miles better) ,, good luck with the rest of it,, and if you need us for anythin just give us a shout ,, if its done for feb 25th get down 2 oulton park , theres a few of us havin a run out,, cheers



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    Re: Mk2 Duratec Escort

    Quote Originally Posted by mk2mania View Post
    if its done for feb 25th get down 2 oulton park , theres a few of us havin a run out,, cheers
    Is that next year?? Count me in for next year

    Got my seat bolted into position and still thinking that the column could do with moving over a bit further yet. Will get a boss and wheel stuck on it and see how it feels.

    Been having a look at hydraulic handbrakes and there is nothing on the market that i fancy much, now the seat is in place i have got a feel for where it would need mounting so have been playing around with a few designs of my own. This is what i have come up with, any thoughts or input on design would be greatly appreciated guys.

    Design is based around using a Tilton 77 series master cylinder with the rear bearing mount.







    Run some alaysis to show stress distribution under a 30kg force loading


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  18. #98
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Mk2 Duratec Escort

    Looks lovely that mate, only question is what are you going to be doing to satisfy the scrutineers for a mechanical handbrake (cable)??

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    Re: Mk2 Duratec Escort

    Been scratching my head on that one for a long while Matt. The only practicle way i can see of doing it is to raise the pivot point of the lever and have cable attachments on the very bottom. The trouble i have is knowing how much throw the lever will need to activate a mechanical brake. I am guessing this will depend on what rear calipers are in use.

    What caliper do you run on yours Matt?

    Does the rulebook state that the handbrake needs to be mechanically activated or mechanically locking? Just wondering how the group n and wrc cars get through it. Am i right in thinking wrc just use a use single circuit hydraulic system and group n use a tandem twin circuit one?

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    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    Been scratching my head on that one for a long while Matt. The only practicle way i can see of doing it is to raise the pivot point of the lever and have cable attachments on the very bottom. The trouble i have is knowing how much throw the lever will need to activate a mechanical brake. I am guessing this will depend on what rear calipers are in use.

    What caliper do you run on yours Matt?

    Does the rulebook state that the handbrake needs to be mechanically activated or mechanically locking? Just wondering how the group n and wrc cars get through it. Am i right in thinking wrc just use a use single circuit hydraulic system and group n use a tandem twin circuit one?
    I don't really know mate what the wording in the blue book is.

    My understanding of it is you have to have a mechanical means of holding the car if the hydraulic circuit was compromised. I use cossie rear calipers on big dia vented discs, probably a little heavy compared to an alloy caliper but I've never had an issue with power from them, I can get all the pad compounds easily, I only need the one set (as compared to running a dedicated spot cable caliper as well) and they obviously satisfy the cable requirement as i modified my GRP4 fabs ratchet lever to acommodate a pair of bike Tandem brake cables that run in two seperate outers and will only tension up if the hydrualics fail.

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    Re: Mk2 Duratec Escort

    Have a look at these:
    http://gartrac.com/shop/forest-grave...handbrake.html
    (link to Gartrac site for reference purposes)

    This is the answer! Cables available off-the-shelf that would work with these calipers and your lever.

    Mark - drop me an email and I'll send you some more info/pictures...

  22. #102
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Mk2 Duratec Escort

    I like those mate

    Might have to put a set on mine. what's the piston advantage over mine? They are just a posh Cossie caliper really

  23. #103
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    Re: Mk2 Duratec Escort

    Thanks guys. They look the the business Tom, having scope for adjustment at the caliper end is perfect. Will have a bit of a re design of the lever this weekend if i get chance.

    ​enquiries@flintec-eng.co.uk

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    Re: Mk2 Duratec Escort

    Matt - these are the calipers I've mentioned to you before (and what's going on the back of mine probably)

    44.5mm piston (your's are currently 40mm piston) so ***quick bit of mental maths*** roughly 20% bigger piston area? Or there abouts.

    The pad area is a fair bit bigger too. And it's a LOT lighter! It won't fit your caliper mounting brackets though, which is a bummer.

    Like i said above though, they don't make this caliper to fit a vented disc - but as we've talked about - your rear brakes probably don't get hot enough to warrant vents anyway, so there's another 4 kgs you can save

    Sorry for the hijack Mark, here's your thread back.

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    Re: Mk2 Duratec Escort

    Looking good Mark.

    Can you incorporate this bracket http://www.ekmpowershop2.com/ekmps/s...e-kit-62-p.asp into the base of your hand brake and then put a pin through it to take the end of the cables? Thats what i am planning on doing to mine.

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    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Mk2 Duratec Escort

    Paul

    That has got to be the biggest rip off in history!!! 99 for that and a crappy bracket. You can get Tandem Cycle rear brake cables from your local shop for about 3 plus a couple of quid for a length of outer.

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by cossie matt View Post
    Paul

    That has got to be the biggest rip off in history!!! 99 for that and a crappy bracket. You can get Tandem Cycle rear brake cables from your local shop for about 3 plus a couple of quid for a length of outer.
    Don't panic i'm not buying it - i will be using the same principal, as like you i have the ratchet grp4 fab vertical handbrake

  28. #108
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    thanks guys, will get up to the lock up with the camera tonight and get a few more pictures taken.
    got a bit done since getting the car back.... front coilovers and tension struts have been overhauled and re-fit




    Some nice work going on there fella...

    Just wanted to enquire as to whether there's any specific reason why your steering arms are fitted upside down on the wrong sides?

  29. #109
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    Re: Mk2 Duratec Escort

    Some great information coming out of this site as ever.

    Quote Originally Posted by GP4 View Post
    Some nice work going on there fella...

    Just wanted to enquire as to whether there's any specific reason why your steering arms are fitted upside down on the wrong sides?
    Well spotted mate. Thanks. These came as a box of bits so had to guess on the orientation from other peoples pictures! Are the on upside down and the wrong side? I think i need to replace them with the cranked ones like these to correct the geometry as im running a lowered steering rack.

    http://www.gartrac.com/shop/steering...anked-arm.html

    Thanks again lads, great work

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    Some great information coming out of this site as ever.



    Well spotted mate. Thanks. These came as a box of bits so had to guess on the orientation from other peoples pictures! Are the on upside down and the wrong side? I think i need to replace them with the cranked ones like these to correct the geometry as im running a lowered steering rack.

    http://www.gartrac.com/shop/steering...anked-arm.html

    Thanks again lads, great work
    Send your existing arms down to Gartrac and they'll modify them. Your genuine Ford arms are far better quality than the stuff being churned out now...keep hold of them chap.

    http://www.gartrac.com/services/steeringarm.htm

    Hope that's of help.... and yes, yours are definitely on upside down on the wrong side strut in those pics!!
    Last edited by GP4; 30-01-2012 at 14:41.

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  32. #111
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    Re: Mk2 Duratec Escort

    Spot on. Never thought of that

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  33. #112
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    Re: Mk2 Duratec Escort

    Braved the lack of warmth this morning and got the engine back in place. Will get cracked on tomorrow and get the last of the oil lines done


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    Re: Mk2 Duratec Escort

    Handbrake ingredients are starting to come together now



    Designed it to incorporate actuation for 2 cables as recommended so it should keep testers and scrutineers happy
    Going to start cutting metal tomorrow if the cnc is free




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  35. #114
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    That's a nice big lump of alloy there!
    http://escort.accelerator.org
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  36. #115
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    Re: Mk2 Duratec Escort

    got her off ebay as an off cut mate, shame about 3/4 of it will end up in the scrap bin!

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  37. #116
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    Re: Mk2 Duratec Escort

    Been over in Switzerland and France on business at Staubli's headquaters, they are developing some new trick motorsport connectors, they did not seem to keen on giving me any smaples yet......... Watch this space!

    Still not had chance to get the handbrake onto the cnc yet but got a few other bits done at the weekend.

    Steering arms are back from Gartrac and look great. Bolted them in place and got some castle nuts for the track rod ends from motorscope. One of the green track rod ends that cam with the cars had a damaged thread so just waiting on a new pair being delivered and the front end can be finished off.



    Gearbox mount is half made. Will gusset it up at a later date.









    .....................really need to do some wiring this weekend

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    Re: Mk2 Duratec Escort

    NICE gearbox mounting mate V cool, nice welding too!

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    Re: Mk2 Duratec Escort

    Thanks mate, its turned out a lot simpler than i imagined. Should work well. Just going to put a bit of gusseting up at the tunnel ends to be on the safe side

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    Re: Mk2 Duratec Escort

    Ahh, wiring, my favourite Then again I am a bit of a masochist

    Keep at it, you're doing a great job
    http://escort.accelerator.org
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    Re: Mk2 Duratec Escort

    cheers mate. im not a hater of the wiring, i quite enjoy it once i have got my head into it. its wierdly satisfying when its going well!

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