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Thread: Mk2 Duratec Escort

  1. #241
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by Joe-Tait View Post
    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
    I think the actual 'cutting time' on the machine will only be 3-4 hours I would have thought. With something this sort of shape a lot of time is spent working out how to hold the part onto the machine without the clamps getting in the way of the cutters.

    Quote Originally Posted by cossie matt View Post
    Mark
    ! 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?
    Matt
    I had a long look at that Matt. The issue with replicating the plastic one is I wanted to retain the raised lip around the spark plug hole to keep any crap out. The hole to mount the coil would be too close to the raised lip to get a small enough diameter cutter in that was long enough to reach that far down into the billet.

    I looked at drilling and tapping a hole to align with the coil hole with the idea of then screwing small posts in. The coils could then mount to the tops of these..........but the tapped holes land right on the o-ring path on 1 and 4

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  2. #242
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Mk2 Duratec Escort

    I did wonder if the machining process had thrown up something that didn't allow it, just shows how difficult it is sometimes to replicate injection moulded parts from billet, definitely not as easy as it seems.

    Great job though. So have you just made a plate that secures all 4 coils and drops onto the step?

    Matt

  3. #243
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    Mk2 Duratec Escort

    I will try get a clearer picture up tomorrow but basically...the plate is a laser cut item that will bolt onto the platforms, into that I will put 4 nutserts for the coils. It also gives me a little room for error on the coils.....these were as difficult to model at the cam cover itself! If there is any error I can just get a new plate laser cut.

    It's always difficult trying to convert both plastic and cast parts into something which is machinable. I only really stole the key dimensions for this part, the mounting holes and the cam sensor position.

    Will try make some more progress on the machining tomorrow...

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  4. #244
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    Re: Mk2 Duratec Escort

    excellent work

    www.gulfpetrolheads.com

  5. #245
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    Re: Mk2 Duratec Escort

    Was not popular for doing this............



    It fits though, just got the top detail to finish off now


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    Re: Mk2 Duratec Escort

    that rocker cover looks the nuts,why dont you cast it

  7. #247
    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!

  8. #248
    Spanner Monkey KENNETH's Avatar

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    Re: Mk2 Duratec Escort

    just read the thread start to finish.
    and your work is awesome lad.
    the one off parts are pure class
    keep up the savage work

  9. #249
    Spanner Monkey Darbo's Avatar

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    Re: Mk2 Duratec Escort

    cam cover is excellent

    would be good if you could tweak it to look like a bda one
    similar to the black one here i think its what a duratecs missing

    http://www.turbosport.co.uk/showthread.php?t=127960

  10. #250
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    Re: Mk2 Duratec Escort

    Thanks lads.I have done a design using 'very similar' text to the BD ones on the top but have not machined it in yet. The rendered images that I have put on here do not show it very well so will get some more out of the design software through the week.

    Very up and down weekend. Tragically last week we lost the mate the standard engine came off so had a big push this weekend........this ones for you Rob

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  11. #251
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    Re: Mk2 Duratec Escort

    Got a lot of the cam cover top detail milled in tonight.........just got the text to add now



    I have a big list of things to get completed this weekend. The end is coming into sight

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  12. #252
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    Re: Mk2 Duratec Escort

    Top class work again

  13. #253
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    Re: Mk2 Duratec Escort

    stunning, will be interested to see what it weighs when finished, but a thing of beauty

    www.gulfpetrolheads.com

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    Re: Mk2 Duratec Escort

    Will get the cover on the scales when i take it off for powdercoating and let you know. I must admit i was a bit worried about the weight earlier on but its not bad at all now.

    Had a big list of things to get on with this weekend but lots of parts failed to turn up
    Hopefully on monday my alternator kit will be here so i can finish off the cooling circuit and give it a decent run. Also an exhaust kit so I can fab my own system.

    All the anodising is back, big thanks to Rob H for sorting that out Just waiting for one more fitting to finish off the fuel system properly.



    Got the handbrake lever anodised too........



    And had a sticker made for the switch panel



    Got the ecu and a couple of relays mounted up under the dash this afternoon too.

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  15. #255
    Pit Crew Decade Plus User 105Ian's Avatar

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    Re: Mk2 Duratec Escort

    That rocker cover looks superb you certainly have some talent when it comes to making one off parts
    Last edited by 105Ian; 06-04-2013 at 18:33.

  16. #256
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    Re: Mk2 Duratec Escort

    Wow that's awesome! loving the machine work.

  17. #257
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    Re: Mk2 Duratec Escort

    Love the rocker cover!

  18. #258
    World Champion Decade Plus User cossymax's Avatar

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    Re: Mk2 Duratec Escort

    Im loving the attention to detail on this car, and love the rocker cover.

    Cracking piece of work my good man.


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

  19. #259
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    Re: Mk2 Duratec Escort

    Thanks lads. Trying to keep the momentum up and get the thing finished now. Will be 2 years as of next month!!!

    Kit has arrived from Tony Law Exhausts. I have got this tacked togther but got no photos yet............



    As far as springs go.........these are nice! Some gucci bike exhaust springs from Akrapovič. Will have to laser cut some lugs to mount them.



    Recieved my semi assembled axle from Tom at Fostek to check bracket clearances on my shell.


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  20. #260
    Pit Crew gorilla1q's Avatar

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    Re: Mk2 Duratec Escort

    lookin' fooookin lovely mate
    When I grow up I will have a MK1 Escort

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

  21. #261
    Tyre Kicker Dan649's Avatar

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    Re: Mk2 Duratec Escort

    WOW! Different level of work there, Brilliant

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  23. #262
    Tyre Kicker Dan649's Avatar

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    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

    Is it only me who cant see the photos?

  24. #263
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    Mk2 Duratec Escort

    Think it's something to do with Mozilla Firefox and photobucket mate. Try a different browser. I was having the same problem. I can see them all using Internet explorer and google chrome now though.

    ​enquiries@flintec-eng.co.uk

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  26. #264
    Tyre Kicker Dan649's Avatar

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    Think it's something to do with Mozilla Firefox and photobucket mate. Try a different browser. I was having the same problem. I can see them all using Internet explorer and google chrome now though.
    Yep, 100% correct, on the Samsung tab now and all is well, fantastic bit of work it is as well, even more fairplay mate, outstanding/intimidating standard of finish
    Last edited by Dan649; 26-04-2013 at 19:40.

  27. #265
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    Re: Mk2 Duratec Escort

    Thanks mate. Glad you got it working. I read in another post its something to do with an issue the everyone else has fixed but Firefox can not!

    Very steady progress over the last couple of weeks. Mainly been tidying up the inside of the car ready for paint. Welded the bracket for the brake and clutch reservoirs onto the shell and also added a relief in the back to allow axle to come fully up without the Watts linkage hitting the boot floor.



    Much rubbing down!!!



    Finally got around to laser cutting some letters to bond onto the cam covers





    .....................which lead to cam cover scrabble



    Hopefully will be able to get the inside painted next weekend then start bolting it back together for the last time

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  28. #266
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    Re: Mk2 Duratec Escort

    Excellent, I like the scrabble/cam cover

  29. #267
    Mechanic waynemk2's Avatar

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    Re: Mk2 Duratec Escort

    :d

  30. #268
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    Re: Mk2 Duratec Escort

    mustard work one of the best restos iv seen credit to you

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    Re: Mk2 Duratec Escort

    Thanks lads. Last week spent most of the week undoing the last 18 months of work stripping the car for an interior paint

    Ready for her trip out..............









    Nice clean white interior



    Ready for home



    Still got the front uprights of the cage to do in black but will wait until the white has fully hardened. Massive thanks to Jeff at Procters Coaches for painting it......and persuading me to do the outside next month

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  33. #270
    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk2 Duratec Escort

    cracking stuff !
    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!

  34. #271
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    Mk2 Duratec Escort

    Would you sell the Raceline rocker cover!

  35. #272
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    Mk2 Duratec Escort

    Just sent you a pm pal

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  36. #273
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    Re: Mk2 Duratec Escort

    Progress has been good but nothing very interesting to show for it. Mainly been rebuilding it after painting the interior. the exterior is getting painted this weekend with any luck then it is going to be flat out getting it ready as quickly as possible, had it 2 years this month

    Bead blasted the cam cover at the weekend ready for powder coating. Its getting done in black, im just unsure whether to polish the high points back through to the ally though........


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  37. #274
    Mechanic waynemk2's Avatar

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    Re: Mk2 Duratec Escort

    Polish back to ally for me... what about the wrinkle finish... just a thought..

  38. #275
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    Re: Mk2 Duratec Escort

    I am liking the sound of poliished ally through the black mate. The crinkle samples I looked at were not really right, one was really fine and I think would look like a poorly applied normal coat and the other was really rough. The finish on that Raceline cam cover is crinkle and thats great.

    Few pictures of tonights progress

    Finally got the wheel spreed sensor routed and mounted.....





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  39. #276
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    Re: Mk2 Duratec Escort

    WOW!!!

    Congrats for what is going on here!! really like the attention to the detail !

    Cheers,
    NRMM.

  40. #277
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    Re: Mk2 Duratec Escort

    Thanks mate.
    Another weekend of good progress. Car is now painted and looking great. Just before we started painting I decided to swap all of the rivet in the arches and spoiler to countersunk ones. Took hours but glad we spent the time doing it.
    Whilst I had use a 2 post lift at the paint shop I got the exhaust mounted to the shell.

    I have had an oil leak on the car since filling it up., between the bell housing and engine. Its just been a steady drip coming off the back of the sump. I had my suspicions that it would be the rear crank seal plate as i had a bit of a ball ache trying to refit the used seal right at the beginning of the build. Got a replacement and spent yesterday stripping it down, gearbox out, cross member off, flywheel off but the seal was completely dry So took the sump off and it looks as if I have not had enough sealer on the mating face between the bottom seal plate and the sump.
    Gave it all a good clean off last night and will put it back together tonight and see if its any better.


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  41. #278
    Spanner Monkey FrEdOoOo's Avatar

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    Re: Mk2 Duratec Escort

    Top JOb!!!

    btw: what tyres have you at front?

  42. #279
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    Re: Mk2 Duratec Escort

    Brilliant work Mark, jaw dropping in fact.

    Just one question, the fuel pump brackets that you've had water jet cut, how do you smooth them before they get anodized? I plan to have some parts cut myself and i was wondering how i was going to smooth out the little ridges form the water jet.

    Thanks,
    Alan.

  43. #280
    Spanner Monkey Alan G's Avatar

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    Re: Mk2 Duratec Escort

    Nice work!
    Can I ask where you got the bracket to hold the wheel speed sensor??

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