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Thread: Mk2 Duratec Escort

  1. #161
    Spanner Monkey

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    Re: Mk2 Duratec Escort

    Will have a look at finding a spec now mate. The Led is bonded onto a small steel mount which is screwed to the aluminium indicator housing. That might give is a bit of sink. Not had chance to test how much heat it generates yet. Will try and have a go at the weekend.

    Designed a rest for pasanger foot well. Swaged it up and got the back welded up today at work. Got it tacked onto the base plate. Just need to check it all fits in and around the roll cage before welding it all together tomorrow


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    Re: Mk2 Duratec Escort

    Wasted a good 2 nights this week messing about with rear lights. The old units which came with the shell were looking a bit tired so bought a pair of new ones off ebay. £20 each, bargain. Got some connectors wired up taking hours of messing about. Tried to test the lights, kept blowing fuses. Obviously thought my wiring of the connectors was wrong. Messed about for hours stripping down the plugs and sockets and testing everything. Turns out it was the bulb holders in the new light units shorting out on themselves. Absolutely shocking quality. Not so much of a bargain.

    And to top it off the connectors would not re assemble after I stripped down.

    Anyway, Spruced up the old light housings and fit them with the new lenses. Everything is tested and working fine now.


    Got some Bosch Motorsport fuel pumps, these have been stripped and rebuild using bronze bushes rather than plastic ones and uprated to 10bar.


    SBD Ultra lightweight flywheel


    Been up tonight and stripped the column off the powersteering. The top bush had loads of play in it. Going to machine a bronze one up at work in the morning

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  3. #163
    Bodger M K's Avatar

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    Re: Mk2 Duratec Escort

    A great build, love how much you are making yourself. Im very jealous, i cant wait to finish the metalwork so i can start assembling mine.

  4. #164
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    Re: Mk2 Duratec Escort

    Thanks, was having a good look through your project last week, its looking good. There have been times where i wished i had bought one that was already on the road! The budget for this thing got blown out of the water months ago!

    Was going to make a bronze bush for the top of the steering column last week then remembered i had a sample of this sfuff on my desk for months. Its a material called Iglidur W300 from Igus, they are manufacturers of plain bearings and bushes. This is one of the materials they manufacture from.





    Was strange stuff to machine but the bush turned out spot on.


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  5. #165
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    Nice!
    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!

  6. #166
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Is that to take out the play in the top of the column me and denz got play there dont know if there is ment to be a bush of some sort there?

  7. #167
    Spanner Monkey

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    Re: Mk2 Duratec Escort

    Yeh mine was the same mate, it looks like there was a bearing in there origionally, all that was left in mine was an outer race which just tapped out for the back of the column. The new plastic bearing has taken nearly all the play out

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    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Any chance you would make a few more???

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    Re: Mk2 Duratec Escort

    Lost the scrap of paper with the dimensions on! Will go and measure it up and get a couple made on Monday

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    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Cheers bro let me know what you want for them

  11. #171
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    Re: Mk2 Duratec Escort

    Got all the dimensions for the bearings Trig so will get two made on Monday.

    The pasanger foot plate is in place and wired up, just need to fasten it down. Going to get it powdercoated and fit some high grip tape on the base and back plate.



    Planning on fitting a Stack ST700 dash display, printed a footprint out so i can start laying out the dash. Going to fit a seperate fuel gauage, probably one on the Stacj 52mm ones. Also a couple of weeks ago i go a warning light dash fitted.....



    ......indicators and main beam are wired up and looks the nuts



    Planning on running just one Bosch pump, with pre and post pump filter. Got all the bits modelled up, started having a play with bracket designs, still not happy with it yet though



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    Re: Mk2 Duratec Escort

    now your just showing off ,looks the nuts im so impressed ,with your tecno skills ,is there a reason your only going one pump ,i know there not known for breaking down but a twin would be nice and have the the back up ,i would be interested in a twin for millie, if you decided that route mate ,

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    Re: Mk2 Duratec Escort

    Yeh thats the only reason Rob, the pumps i got hold of are uprated so hopefully should be more reliable than the already reliable standard ones. No issues making a twin bracket when i get these done though

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

    Lovely work Mate. Where did you get that warning light bar? I've run an ST700 for years and I've been after a compact warning light setup like that. Looks really neat.

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    Re: Mk2 Duratec Escort

    Can remember seeing them on kit cars years ago and not seen them for ages. They are made by a company called Lighting Looms and Demon Tweeks are selling them now in two formats, the horizontal one like mine or a T shaped one. Really simple to wire and super bright.

    http://www.demon-tweeks.co.uk/perfor...g-light-module

    To mount it I milled a long 10mm slot into my dash back plate and then two 4mm mounting holes on each side.

    http://www.lightninglooms.co.uk/LLDE...%20Drawing.pdf

    What rev range are you using on your dash Matt?

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    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!

  17. #177
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    Can remember seeing them on kit cars years ago and not seen them for ages. They are made by a company called Lighting Looms and Demon Tweeks are selling them now in two formats, the horizontal one like mine or a T shaped one. Really simple to wire and super bright.

    http://www.demon-tweeks.co.uk/perfor...g-light-module

    To mount it I milled a long 10mm slot into my dash back plate and then two 4mm mounting holes on each side.

    http://www.lightninglooms.co.uk/LLDE...er Drawing.pdf

    What rev range are you using on your dash Matt?

    0-4-10500 mate, and I need most of it!!! New engine will go to 9600 I've got the aux gauges with the configurable outputs so I can use them to drive the warning lights too.

    Cheers for the info, I'll go and have a look for one. I've heard of lightning looms before.
    Last edited by cossie matt; 04-09-2012 at 22:08.

  18. #178
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    got the bush today buddy cheers dont think you sent me your paypal yet???

  19. #179
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    Re: Mk2 Duratec Escort

    Work priorities have meant i have opened the garage door once in the last 5 weeks

    Need to get the momentum going again, ordered my dash and fuel gauge.
    Did a quick layout on the CAD software to check everything fits in ok then cut the dash panel on the cnc milling machine at work to get some nice clean holes





    The two small holes on the left are pilot holes for the rotary knob and button for the Stack dash.
    Got the dash wired up tonight, looks great but forgot to get a photo!!

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  20. #180
    Racer Decade Plus User mexicotait's Avatar

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    Re: Mk2 Duratec Escort

    Could you possibly send me the dimensions of the bush
    I need to make one for my columm
    Hexham and District Motorclub

  21. #181
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    Re: Mk2 Duratec Escort

    Yeh just PM me them through. Not sure I have any of the bearing plastic left but I do have lots of high density polyethylene which will be just fine

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    Re: Mk2 Duratec Escort

    I meant could you give me the dimensions
    I know its lazy but i just be bothered to take the columm out to measure it
    Hexham and District Motorclub

  23. #183
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    Re: Mk2 Duratec Escort

    Sorry never read your message poroperly! Yeh will dig them out and post them on here

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  24. #184
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort


  25. #185
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    Re: Mk2 Duratec Escort

    Got back to the workshop this weekend. Made a start on a bias adjuster for the pedal box. Got a few bits to do for other people through the week then I will get the adjuster knob done.
    This is the cable adapter to go onto the balance bar.


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    Re: Mk2 Duratec Escort

    Just trial fitted these monsters from SBD . Time to get my finger out and make some progress







    Going to make some bungs to fill the standard injector holes and i have a big list of fitting to order now for the fuel system next.

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  27. #187
    Part of the furniture Decade Plus User trig's Avatar

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    Re: Mk2 Duratec Escort

    Good to see more progress buddy gona be a lovely car

  28. #188
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    Re: Mk2 Duratec Escort

    Throttle bodies.....Yum!!

    I've seen those before somewhere

  29. #189
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    Re: Mk2 Duratec Escort

    Got some front brakes bolted on this afternoon.
    Tomorrow I need to get the throttle cable worked out and do a bit more on the pedal box bias adjuster.


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    Re: Mk2 Duratec Escort

    And I think I've seen those calipers somewhere before

    I did ask Matt about the throttle cable!

  31. #191
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by FOSSIE View Post
    And I think I've seen those calipers somewhere before

    I did ask Matt about the throttle cable!
    They have done the rounds by the sound of it mate

    Had a quick play with that throttle cable tonight, it looks more than flexible enough to come out and accross the front of the bulkhead which should keep it fairly tidy. Need to go into work in the morning and make a couple of special washers to go in the existing hole in the bulkhead to mount the cable adjuster.

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  32. #192
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    Re: Mk2 Duratec Escort

    Cracking build mate just read it all, have you done any internal work to the engine ? Or are you getting it going then do engine work layer on when time and funds allow ?

  33. #193
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by Mitchy View Post
    Cracking build mate just read it all, have you done any internal work to the engine ? Or are you getting it going then do engine work layer on when time and funds allow ?
    Thanks Mitchy. The internals are standard at the moment. As you have worked out, what I am planning is to get the car going and get some 'steady' miles on it. Hopefully this will prove everything else mechanically. Then strip it, get the internals upgraded and paint the shell. Hopefully by the summer

    Made this to screw on the ouside of the bulkhead behind the pedal for the throttle cable adjuster to mount in. The adjuster on the throttle body end is on the underside and would be a bit tricky to get to. Need to make an adapter to mount the cable to the pedal this week.


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  34. #194
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    Re: Mk2 Duratec Escort

    Ideal hope to see it up and running soon and hope everything goes smoothly lol

  35. #195
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    Re: Mk2 Duratec Escort

    Made an adapter to secure the throttle cable to the top of the pedal




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  36. #196
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    Re: Mk2 Duratec Escort

    Been busy on wiring another rally car for a mate over the last few weeks so time spent on mine has been poor.

    Have got the foot plate back from powdercoat and stuck the grip tapes on



    Also made a bias adjuster knob for the pedal box






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  37. #197
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    I never thought I'd say this to another man, but I love your knob

    How long did that take you to make then? I assume it was done on a CNC machine?
    http://escort.accelerator.org
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  38. #198
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    Re: Mk2 Duratec Escort



    It was not a long job to be fair. About an hour in total.
    Initially turned on a CNC lathe, then milled on a 3 axis cnc milling machine and finally finished off on a conventional lathe. We have just got this new milling machine.



    I have not found any car parts that I can use it for though

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  39. #199
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    Nice toy !
    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!

  40. #200
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    Re: Mk2 Duratec Escort

    great work fabricating most of the parts.

    haveyou got a list of parts you are selling yet?

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