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Thread: Mk2 Duratec Escort

  1. #201
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    Re: Mk2 Duratec Escort

    Thanks Dave. I have not got a list done yet but its a good idea. I will start putting one together with photos of various parts.

    Just done some lower seat mounts. The photo below shows my origional ones. I need to use the very bottom mounts on the brackets with me being so long!!! The top of the origional bracket covered the harness holes so got some lower ones made doing away with a few top holes.

    Origional.....


    New......



    Bit of digression....was on a test day yesterday with the coach2.com/procters coaches rally/rallycross cars at Blyton Park.

    Ex Richard Burns WRC Impreza


    560HP Focus Rallycross Supercar


    Kev took me on a few tyre destroying laps in the Subaru. Tried to get a bit of video footage but gave up after a short time! The video does not really do it any justice but what a piece of machinery it is!
    http://s1231.beta.photobucket.com/us...c0ca4.mp4.html

    Also had Andy in his 200HP 1400 Nova, Joe in his 106 and another guy in a ex Italian touring car series Alfa 155.

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  2. #202
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    Re: Mk2 Duratec Escort

    You mean he didn't let you have a drive? :p

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    World Champion Decade Plus User alladdin's Avatar

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    . We have just got this new milling machine.
    not from s.wales was it

  4. #204
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by FOSSIE View Post
    You mean he didn't let you have a drive? :p
    No, he didnt seem overly keen

    Quote Originally Posted by alladdin View Post
    not from s.wales was it
    Not sure to be honest, it came new straight from the supplier. Their UK HQ is in Devon but sure someone said thay have a place over Lancashire way somewhere.

    This is what has kept me away from my car for the past few weeks.......

    ....complete rewire on a 106gti rally car


    .........wont be volunteering to do another one!!

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  5. #205
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    Re: Mk2 Duratec Escort

    Bought some PIAA super bright headlights/bulbs and been on fitting/wiring them for the last few nights.







    Got the front indicators to wire up tomorrow night and that should be all the lights done.

    Been on doing other various bits and pieces like fitting a fibreglass bonnet I bought from a local rally guy and fit some aerocatches to that. It does have a small amount of battle damage to the front o/s that i will repair at some pont.

    Made a start on the fuel system. Got a Fuel Lab pressure regulator and Siemens injectors from the America. Ordered most of the fittings I need and will make a start on installing it all at the weekend.






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  6. #206
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    Re: Mk2 Duratec Escort

    Coming together well mate.

    I've got those headlights and they are the business! Did you get them from Historic Rallysport? As they do cost a few quid!

  7. #207
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    Re: Mk2 Duratec Escort

    Thanks Paul. I ended up getting these from Motoscope as they are only 5 minutes up the road from me. Your right they are not cheap....... think half of the value is in those bulbs!

    Looking at your banner....I need to get a big hole in the slam panel for a cold air feed. What did you use to cut yours mate?

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    Racer Decade Plus User mexicotait's Avatar

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    Re: Mk2 Duratec Escort

    Do you know andy fawcett or derek fawcett
    I see andys nova in the background of your pic
    Hexham and District Motorclub

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    Re: Mk2 Duratec Escort

    Coming together well

    Nice build , and some lovely touches

  10. #210
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    Thanks Paul. I ended up getting these from Motoscope as they are only 5 minutes up the road from me. Your right they are not cheap....... think half of the value is in those bulbs!

    Looking at your banner....I need to get a big hole in the slam panel for a cold air feed. What did you use to cut yours mate?
    The hole in my signature was made with a big hole saw - but its even bigger now so i can get the cold air feed from the air box right up against the grill

  11. #211
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by mexicotait View Post
    Do you know andy fawcett or derek fawcett
    I see andys nova in the background of your pic
    Its Any i know, through rally and rallycross mate. His nova is a stunning car, real credit to him

    Quote Originally Posted by FrEdOoOo View Post
    Coming together well

    Nice build , and some lovely touches
    Thanks Fredo. Starting to see the end in sight now! Great work with that Mk1

    Quote Originally Posted by Paul C View Post
    The hole in my signature was made with a big hole saw - but its even bigger now so i can get the cold air feed from the air box right up against the grill
    I have a few hole saws at work but nothing that big....think I will have to pepper it with a load of 2" holes!!


    Got the front idicators wired up tonight and some proper earth connections for all the lights up front.
    Thats the wiring for the lights done



    This has been work in progess for a few months now........
    Fuel pump/filter brackets

    Decided to run two pumps after all......
    Plan is, -8 from fuel tank into the 180° fitting, into pre filter with 55 micron metal filter. On the far side is a manifold idetical to the one on this side. That feeds the two 044 pumps. Through check valves and into this side manifold. Out of there and through the high pressure filter with pleated 8 micron paper filter...... -6 lines down to the engine bay and returning to the tank


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    Racer Decade Plus User mexicotait's Avatar

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    Mk2 Duratec Escort

    Derek built the car
    Hes got some skills
    Much like yourself
    Hexham and District Motorclub

  13. #213
    Pit Crew gorilla1q's Avatar

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    Re: Mk2 Duratec Escort

    I like the fuel pump/filter design some proper skills bud
    When I grow up I will have a MK1 Escort

    I must be all growed up now then and paying for it!

  14. #214
    Racer Decade Plus User mexicotait's Avatar

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    Re: Mk2 Duratec Escort

    And how did you earth the headlights
    Im looking to add some additional earths but need some ideas
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    Re: Mk2 Duratec Escort

    Thanks lads

    At the moment I have earthed the headlights and idicators to the front M8 bolt where the bumper bracket mounts to the shell. I was only doing this for testing purposes but it will look quite tidy once p-clipped up so it can stay! Will try and get a photo tomorrow.

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    Re: Mk2 Duratec Escort

    Just read your thread from start to finish - fantastic work!!!!

  17. #217
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    Re: Mk2 Duratec Escort

    Thanks Paul Not long until its getting started now

    Just cut all load of aluminium parts on the waterjet.........



    ........and started machining the fuel pump/filter bracket



    Will be making a start on the manifolds tonight

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    Pit Crew Decade Plus User PaulAlex's Avatar

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    Re: Mk2 Duratec Escort

    Now thats just showing off!! I'm still wincing at the cost of my fuel pump setup

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    Re: Mk2 Duratec Escort

    They do seem to be priced a little sleeply! If I took into account how long I had spent messing around with the design of mine, theirs would be a bargain!!

    I am making 3 sets of these brackets/manifolds. Got the 1/4NPT to M12x1.5 adapters partially machined this weekend. Just need to add the spanner flats and cross drill the ports on them tomorrow.



    Just got the manifolds left to do this week. Still waiting on a special cutter for machining the insides which should be arriving in the morning.


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  20. #220
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Mk2 Duratec Escort

    I'll swap you one of these setups for a power steering unit Mark???

  21. #221
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    Re: Mk2 Duratec Escort

    Matt you have PM

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  22. #222
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    Re: Mk2 Duratec Escort

    Adapters are now finished

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    Re: Mk2 Duratec Escort

    lovely work, same injectors as I am using, work really well

    www.gulfpetrolheads.com

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    Re: Mk2 Duratec Escort

    Thanks mate, what management are yo running them off?

    Now the wetaher has warmer up a little bit I have been on getting the last bits of the fuel pipes. I have made a little -6 extension to go on the end of the fuel rail to help align the fittings on the rail with the fittings in the bulkhead.



    I will get a picture of it in place tonight........................

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    Re: Mk2 Duratec Escort

    Been crap at keeping this up to date over the last few weeks......have made some good progress on the build though.

    Flywheel and starter have been fitted. Starter motor is wired and works nicely.
    Lowered the steering column down by 15mm at the point where it mounts onto the dash panel. This has impoved the position of the steering wheel massively.
    Got the manifolds finished for the fuel pump brackets





    Also skimmed the oil filter housing flat and taped it out to take an M10x1 oil pressure switch






    This is an origami bracket for mounting the wheel speed sensor to the strut. Making a few of these so done another hole for a trip meter sensor if people need to run one of those too. Should have the stainless steel ones cut and fabricated by the end of next week.



    Few small parts to do/buy next week then should be ready to start it up.

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    Re: Mk2 Duratec Escort

    Great work, great efford.

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    Re: Mk2 Duratec Escort

    nice work mate taking things to the next level few quids worth of tools you got there, love your work,when you fitted the engine what was stopping you from pushing engine back towards the baulk head keep the weight inboard,is there a reason its so far forward,rick

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    Mk2 Duratec Escort

    Thanks Rick. Can't begin to imagine how much harder doing this build would be without all the gear at work.

    On the engine position.......I am disappointed with where it is, I only have myself to blame! Did the engine mounts before I had it fully mocked up. Once I have got the car proven and had a bit of fun in it it will be getting stripped for a complete paint inside and out. I think at that point i will shift it all back. I think there is about 40mm to gain without things getting too tight at the back.

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    Re: Mk2 Duratec Escort

    nice billet gearbox xmember like your handbrake

  30. #230
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    Re: Mk2 Duratec Escort

    Really nice build. A JRE built Duratec is one of the best Mk2 Rally cars I have ever heard. Wish I had the money to build one like this!!

  31. #231
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    Re: Mk2 Duratec Escort

    Thanks lads. It will be getting started this week hopefully.
    ECU is down at SBD getting an upgrade and base map put in. Coils, air temp sensor, crank sensor and coolant sensor are on their way too. Just waiting on the anodising to come back then the fuel system can be completed.

    Few bits for anodising


    Purged up the oil system over the weekend..........made this pulley for the drill and used a long timing belt to the air out of the system.


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  32. #232
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    Re: Mk2 Duratec Escort

    very good engineering work going on here

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    Re: Mk2 Duratec Escort

    Came so close to starting it last weekend! Coils beeing the last parts to fit and.............whey would not fit!! The mounting lugs would not fit within the Raceline cam cover

    Thought about modding the coils just to get the thing fired up but rightly decided against it.

    After a lot of headscratching and time with the verniers decided to make a new cam cover



    Laser cut profile to check the hole positions










    3 bin bags of swarf later.......................



    This is my design..... gone for an old style design like the Hart Beattie motors



    .....and how I plan on mounting the coils



    A couple more nights at it and it should be somewhere near finished

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    Racer Decade Plus User mexicotait's Avatar

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    Re: Mk2 Duratec Escort

    Ive just started my cnc training i cant wait to start this sort of thing
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    Re: Mk2 Duratec Escort

    Awesome

    What sort of price realistically would that cost to have made? Material + setup etc

    Going to design my own split rim centres when work calm's down a bit, then hopefully get them made up
    Screaming 1300 mexico rep

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  36. #236
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    Re: Mk2 Duratec Escort

    Awesome!
    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!

  37. #237
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    Re: Mk2 Duratec Escort

    Thanks lads. Its difficult to appreciate how much things like this would cost to have made out. The billet of material for this was only £125+vat which I was quite surprised about. But then I have probably spent best part of 10 hours messing with various designs until I came up with one I was happy with. So far its been on the milling machine for about 5 hours and i would say there is at least another 3 hours to go.

    So that would be around 18 hours, usually about £55/hr for a machine shop, + materials. So it would be getting on for £1200 I would think
    Obviously this is ridiculousness for a cam cover but that is the nature of 1-off parts. If there was to be a second one made, all the deign value, what would be £550, is already paid for.

    I am lucky to have all the machinery at my disposal so its really only cost me £125 for the material and a few headaches working out hole positions and o-ring paths!!

    If there is a decent amount of interest in these I would possibly consider doing some low volume casting/injection molding.

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  38. #238
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    Re: Mk2 Duratec Escort

    Ha that's brilliant.
    'Im having trouble with this rocker cover, I know I'll make a brand new billet one.'
    Looks fantastic, designing something like that is a great skill!

  39. #239
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    Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    Thanks lads. Its difficult to appreciate how much things like this would cost to have made out. The billet of material for this was only £125+vat which I was quite surprised about. But then I have probably spent best part of 10 hours messing with various designs until I came up with one I was happy with. So far its been on the milling machine for about 5 hours and i would say there is at least another 3 hours to go.

    So that would be around 18 hours, usually about £55/hr for a machine shop, + materials. So it would be getting on for £1200 I would think
    Obviously this is ridiculousness for a cam cover but that is the nature of 1-off parts. If there was to be a second one made, all the deign value, what would be £550, is already paid for.

    I am lucky to have all the machinery at my disposal so its really only cost me £125 for the material and a few headaches working out hole positions and o-ring paths!!

    If there is a decent amount of interest in these I would possibly consider doing some low volume casting/injection molding.
    Thanks a lot for the detailed reply, I guessed it would be around £75 per hour but was miles out on the machine time. Keep up the good work, all the design time is paying off, looking at these parts
    Screaming 1300 mexico rep

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

    Mark
    That cam cover looks bloody gorgeous, would love one of those on mine but at that sort of cost I think the lightweight plastic will have to do for now! Is there now way of leaving the little posts like the original for your coils or was it too difficult to replicate in the Ali?

    Keep up the awsome work mate, can't wait to hear her running.

    Matt

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