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Thread: Mk2 Duratec Escort

  1. #121
    Spanner Monkey

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    Re: Mk2 Duratec Escort

    Origami seat mounts............to check the fit



    Got these cut and folded out of 5mm aluminium. Will probably get them powdercoated black once i have a batch of parts to be done


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  2. #122
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    Re: Mk2 Duratec Escort

    I have been a bit slack with the updates lately. Work commitments have slowed the build down massively over the last few weeks. The seat brackets I made fit perfectly. Contemplating making some shorter ones which will do away with the top couple of mounting holes, getting rid of the dead area of bracket and saving a few g's. Im sure most people will only use the lower portion of the mounting



    Had a big spend with Ralloy earlier in the month.

    Radiator
    Duratec Hose Kit
    Low profile pull fan
    Fuel tank
    VDO sender
    Filler bowl
    Hose kit



    Tried fitting the tank and it would not quiet fit onto the tank platform Looked as if the platform was positiond too close to the firewall. Got it cut out and will have a look at welding it back into a more suitable position at the weekend if I get chance.



    Started on wiring the column stalks. Its taking time but looks tidy. Got the lights done last night. Going to have a look at the wipers and indicators tonight.

    Also started designing driver and passanger floor trays. Not happy with them yet though

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  3. #123
    Pit Crew Hoogi's Avatar

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    Re: Mk2 Duratec Escort

    Such a great build..................you sure have skills.

    The new seat side mounts are very impressive.

  4. #124
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    Re: Mk2 Duratec Escort

    Thanks mate, enjoying every minute of doing it.

    Finally got my handbrake onto the cnc miller at work on saturday.







    ..................6 hours later





    Could not be more happy with the outcome

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  5. #125
    Mechanic roosie's Avatar

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    Re: Mk2 Duratec Escort

    Hi mate are you selling the seats mounts? if so i need 2 pairs send me a pm if you are with a price.

  6. #126
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    Re: Mk2 Duratec Escort

    Yes i am going to start selling them. Will get a thread started with various parts for sale. Will get you a price pm'd over this afternoon.

    Thanks
    Mark

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  7. #127
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    ^ hours to machine the handbrake? Guess you won't be making a lot of them then!
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
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  8. #128
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    Re: Mk2 Duratec Escort

    Too true! There was a lot of head scratching taking place! Working out where best to put clamps and avoid craching cutters. The actual cutting time was probably closer 2 hours!The price would have to be right to go through the stress of making another one

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  10. #129
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    Re: Mk2 Duratec Escort

    Got a little bit done on Saturday. There was not enough clearance between the bottom radiator connection and the dry sump oil pump to get the hose on without issue so took it to work and modified it. Had to cut one corner of the mounting fange away slightly to allow the connection to be rewelded more vertically than the standard postion.



    Forgot to get a photo of it before i put it back in the car Here is one of it back in place with the hose on. Its given me around another 15mm between the pulley and the hose.



    Got a special hose seperator designed to go in the engine bay to keep the oil lines tidy. They will seperate 2 x -12 and 1 x -10 hose. Also going to do a load of -8 and -6 combination clamps for the fuel lines whilst im on with them.



    The top radiator hose and water rail bolted on without issues.


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  11. #130
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    Re: Mk2 Duratec Escort

    Been slowly chipping away at the wiring this week. Not much to report on that though.

    Someone else posted a thread up about cutting carbon fibre last week and that got me thinking.
    I currently have a waterjet cutting pump and head at work which I am using for a development project for cutting food. Thought I might as well take advantage of it and cut some carbon profiles.

    Got the head mounted onto the end of a 6 axit Staubli robot which i use for demonstrations and trials. Drew the parts up on Solidworks and printed them out on a 1:1 scale and taught the positions into the robot.

    This is the pump. KMT 50hp unit. 60,000psi, that 4,137 bar!



    The robot i used is a Staubli TX60 6 axis. With the KMT cutting head on the end of the 6th axis. Using a 0.1mm saphire tip.





    Some of the cut parts
    -Radiator surrounds
    -Cam cover infills
    -Dash vent covers
    -Dash centre infill



    Admittedly at little over the top but its been a good exercise.

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  12. #131
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    Very cool, I hate to think how much all that kit would cost!
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
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    1972 MK3 Cortina 1600XL
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  13. #132
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    Re: Mk2 Duratec Escort

    To be fair mate, that's just showing off

    Great work though How long have you got that waterjet to play with, I mean evaluate?!

  14. #133
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Cracking job bud

  15. #134
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    Re: Mk2 Duratec Escort

    Nobody like a smart arse.................

  16. #135
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    Re: Mk2 Duratec Escort

    Its going back to Sweden tomorrow Will get it back in a few weeks with any luck. It just spends its time traveling around Europe and the Nordics for trial and development purposes.
    The pump is about £50k Robot of that spec, built for the food industry its between £18k-20k

    Had another job for it tonight before stripping it down. Bought some carbon door cards and rear 1/4 cards off eaby months ago. The rears did not fit because my shell is tubbed out. Made a quick cardboard template last night, set the pair up back to back on the waterjet tonight and trimmed a chunck off to suit the tubs.



    Also made a plate to replace the cast EGR valve blank. The cast Ford item was too thick and foulded the return on the RetroFord waterrail. Just marked this out and cut it out with the grider from some 3mm stainless.


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    Re: Mk2 Duratec Escort

    Wiring........wiring.........wiring


    Mainly been adding to the new loom and connecting it up to the standard escort column stalks. Got sick of trying to solder wires in fresh air so made this clamp from bits at work. It has made the task much less painful!



    No problems soldering the sidelight/headlight stalk, came to do the indicator stalk and had no joy at all getting the solder to take to the old wires. Gave up with it and did some research. Solution was to use some solder flux. Had some plumbers flux but luckily found an article that mentioned that plumbers flux is corrosive to copper wires. Contact flux is what was required. One of my electrical suppliers in Leeds had 4 tins left at £2.20 each and then discontinuing the product. So i got them all. Makes life so much easier, wont be soldering without it from now on!



    Also picked up some wheels I won on ebay. 8x13 Minilites with new rubber. Absolute bagain


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    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Looking good buddy ive been getting on with mine too.
    I wouldn't mind some of them fuel line separaters if your making them???

  19. #138
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    Re: Mk2 Duratec Escort

    Yeh i will get a batch cut. Do you know approximately how many you will need? I was thinking i will need 10-12.

    Also do you know which fuel line you have? I am planning on using the PTFE lined stainless stuff. So my clamps will be 11mm and 13.5mm for AN-6 and AN-8......... Not a big issue doing a different sized one though if your pipe diameters are not quite the same

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  20. #139
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    Re: Mk2 Duratec Escort

    Very busy with work at the moment. Managed to get a couple of hours in on the car in today.

    Done away with the duct in the rear quarter for the oil lines to pass through. Bolted them down to the top of the tub and cut a pocket in the panel. Was not happy with the old idea and this is much more servicable.



    Got the oil line clamps for the engine bay picked up from the profilers. Machined them yesterday at work and they fit perfectly



    ............................still chipping away at the wiring

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  21. #140
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    looks good bud I used the hard line system in the end as its sooooooo much cheaper than the braided teflon stuff...

    I bought 8meters of hard line with fittings for about £50 then 3meters of teflon braided with fittings was about £150...

  22. #141
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    Re: Mk2 Duratec Escort

    Dont tell me that! Sure im up to about £600 for the oil lines! If I was to start again i would put the tank in the engine bay like the Ralloy setup. Bit cluttered under the bonnet but much more simple.

    Click image for larger version Name:	Mk 2 Escort.jpg Views:	1344 Size:	48.1 KB ID:	55171

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  23. #142
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    Re: Mk2 Duratec Escort

    Got a few more wires to play with.......and an ecu



    Got this off my brother for my birthday! Has to be the best stone garden orniment going..........


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  24. #143
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    nice matey Im bring to keep my engine bay as empty as posable as the rest of the car is a shitter lol...

    My engine has just gone back as I couldn't get oil pressure but the guys sound said he would get it sorted and back to me by next week...

  25. #144
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    Re: Mk2 Duratec Escort

    Wot a car bespoke stuff is the way foward. I should of listened at school ha ! Quality build tho. Every credit to u.

  26. #145
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    Re: Mk2 Duratec Escort

    Thanks for the comment, glad the hours of head scratching are being appreciated!

    Did not get a great deal done over the bank holiday weekend.
    The one thing i did get done was to sort the fittings out for the handbrake. Assuming the master cylinder would be for a -3 and a -4 fitting, I got what i thought i would need from Motorscope. Got home to try them and it turns out the Tilton cylinder uses a -3 (3/8UNF thread) and a 9/16UNF thread, which is not -4!

    Gave up trying to find an off the shelf adapter and made one



    Gave me chance to do some old school screw cutting which i have not done since i served my apprenticeship



    9/16UNF to 3/8UNF Adapter



    Cylinder with -3 banjos fitted

    Next on the design list is a modular antiroll bar for the front

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  27. #146
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    Re: Mk2 Duratec Escort

    Excellent, wish I had your machining skills mate

  28. #147
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    Re: Mk2 Duratec Escort

    I am in awe of your skills.

    Keep it up.

    Cheers

    Matt

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    Re: Mk2 Duratec Escort

    Isnt screw cutting fun
    Hexham and District Motorclub

  30. #149
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    Re: Mk2 Duratec Escort

    amazing car keep up the good work

    ~~ mk5 fiesta duratec powered ~~

  31. #150
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    Re: Mk2 Duratec Escort

    Thanks lads. Progess seems to have ground to a halt at the moment though. Having a cheap month in order to get the engine going possibly next month. Still need to buy

    Alternator
    Flywheel
    Starter Moror
    Throttle Bodies
    Fuel System

    All i have manged to get done is get some fuel line clamps waterjet. Machined them at work this morning.





    ....................got about 35 spares if anyone wants to buy some!



    Also got most of the front end modeled up ready for designing the anti roll bar. Going to draw the legs up tonight if i get chance.

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  32. #151
    Spanner Monkey Pikey15's Avatar

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    Re: Mk2 Duratec Escort

    Very nice work, what's the CAD package that you're using? I'm trying to get my head around Solidworks at the moment for work

  33. #152
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by Pikey15 View Post
    Very nice work, what's the CAD package that you're using? I'm trying to get my head around Solidworks at the moment for work
    I use Solidworks too, I use it for work so know the software well. I have been trying to model up most of the components on the car to make it easier to design my own parts. It has been a struggle measuring the cast parts in order to get an acurate model but im nearly there.

    Got most of the front end set up done this afternnon



    One thing i do not have much experience of is surface modeling needed to draw the contours of the shell. Got the important parts done, would be nice to stick a shell over the top of it all though.


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  34. #153
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    Re: Mk2 Duratec Escort

    U stil got sum hose clamps left ?
    Wot hose size do u use with them ?
    Cheers

  35. #154
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    These are for PTFE lined hose 1 x -6 and 1 x -8. I can make any size combination required for any type of hose. Pm me if you need any more info

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    I use Solidworks too, I use it for work so know the software well. I have been trying to model up most of the components on the car to make it easier to design my own parts. It has been a struggle measuring the cast parts in order to get an acurate model but im nearly there.

    Got most of the front end set up done this afternnon



    One thing i do not have much experience of is surface modeling needed to draw the contours of the shell. Got the important parts done, would be nice to stick a shell over the top of it all though.

    That's looking fantastic. Surface modelling is something that I'm quite interested in as well, I'm slowly trying to model my Mk1. I have a PDF guideline/tutorial on how to model a Camaro if that's any use to you

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by Pikey15 View Post
    That's looking fantastic. Surface modelling is something that I'm quite interested in as well, I'm slowly trying to model my Mk1. I have a PDF guideline/tutorial on how to model a Camaro if that's any use to you
    Yeh would be good to see that. Thanks. If i get time its something i would not mind having a go at. Will send you a pm

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    Re: Mk2 Duratec Escort

    Got a few parts powder coated last week


    Front bumpers


    Handbrake bracket


    These are some strut top plates I made for a local guys Capri. Allowing him to bonnet fit gas springs

    Slowly making my way through the wiring. All switches are wired, looms to where they need to be and tested. Just need parts to go on the end of the wires!

    ..............front indicators

    Had 4, all of which were in a bit of a state, non of them working.


    Messed around for an hour trying to salvage various parts resulting in cracked housings and several twisted bulb housings. Gave up and decided on upgrading them.

    3W High power LED
    11 Ohm resistor


    Drilled out and tapped the housing to take an M20 sealing galnd


    Soldered up the resistor to the LED and made a mock up mount


    Finished mock up



    Works a treat and are super bright
    Need to sort out some of the superseal plugs and sockets and get another LED and resistor ordered for the other side then get them fitted.

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  39. #158
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    Top work mate, have you got enough heatsinking for that bad boy LED?
    http://escort.accelerator.org
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  40. #159
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    Re: Mk2 Duratec Escort

    Not thought about that I assumed that an LED would have less heat loss than a filament type bulb?
    I have not tried them for any length of time. Will have to try one permanently on and check the heat. Will let you know how i get on!

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    Re: Mk2 Duratec Escort

    The issue with them is that the LED needs to dissipate the heat it makes otherwise it'll burn out.

    Because it's only on 50% of the time you can halve the steady state heat dissipation. You still need to have a look at the datasheet for the device to see whether it needs an external heat sink or not!
    http://escort.accelerator.org
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