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Thread: Mk2 Duratec Escort

  1. #321
    Pit Crew gorilla1q's Avatar

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    Re: Mk2 Duratec Escort

    Nice one mate Must admit I'm a bit gutted as I loved reading this build and looking at the pics lol Will it be at CF next year want a closer look at them mods
    When I grow up I will have a MK1 Escort

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

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    Re: Mk2 Duratec Escort

    Thanks mate, it really has been a pleasure doing it but don't worry this is not the end of the escort project, I will now focus on developing it. First of this big list of ideas is a new front suspension set up, bespoke billet uprights on adjustable dampers, have a lot more researching to do yet though. Then it will be to increase the power up to the 250 bhp region.

    I have another project in mind already for once things start to settle down work wise, and it is something which I can go wild with the engineering on, not so limited by the regulations as the escort.

    As for classic Ford, yes it will be there I would think.

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    Racer Decade Plus User mexicotait's Avatar

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    Re: Mk2 Duratec Escort

    Happy days mark
    Its looking great
    Hexham and District Motorclub

  4. #324
    Pit Crew gorilla1q's Avatar

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    Thanks mate, it really has been a pleasure doing it but don't worry this is not the end of the escort project, I will now focus on developing it. First of this big list of ideas is a new front suspension set up, bespoke billet uprights on adjustable dampers, have a lot more researching to do yet though. Then it will be to increase the power up to the 250 bhp region.

    I have another project in mind already for once things start to settle down work wise, and it is something which I can go wild with the engineering on, not so limited by the regulations as the escort.

    As for classic Ford, yes it will be there I would think.
    When I grow up I will have a MK1 Escort

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

  5. #325
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    Re: Mk2 Duratec Escort

    Really good build thread, thanks so much for sharing. Would you be able to post a few pictures of the finished engine bay? All the best.

  6. #326
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    Mk2 Duratec Escort

    No problem mate. Will get some photos over the weekend and stick them on here for you.

    ​enquiries@flintec-eng.co.uk

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by nathanblaise View Post
    Really good build thread, thanks so much for sharing. Would you be able to post a few pictures of the finished engine bay? All the best.
    These any good to you mate?






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  9. #328
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    Re: Mk2 Duratec Escort

    Thanks mate, really good. Wanted to get some inspiration for my duratec install which should be underway soon. All the best and hope to see a section under competition cars to see how she goes. CheeRS

  10. #329
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    Re: Mk2 Duratec Escort

    Sorry for the lack of updates but until the weekend there has not really been any. Got a good few hundred miles on the car now and it has been great fun. Only teething problems to date been......

    -an oil leak on the gearbox, turned out to be the lid not being sealed
    -dodgy master switch
    -water leak on the inline restrictor I put in to create some back pressure in the cooling system

    So on Saturday was heading up north to see Tom at Fostek and called into Motoscope to pick up a master cylinder. Ended up coming out with this beauty.



    So got it fitted on Sunday afternoon.

    Few issues with the fitting, all relating the the concentric slave cylinder........

    This is how the cylinder was mounted in the bell housing with the old box, the cylinder mounted into the back of it.



    With the new box, the cylinder needed to mount on the front of the box, not the back of the bell housing. With only a small 50mm hole in the bell housing we had to open her up a bit! this allowed the front of the 60G to pass through the bellhousing.



    Looks rough above, but 10 minutes with the air sander and it was a decent round(ish) hole

    Needed to make a new gearbox bracket as the mountings were different on the boxes.

    That sorted, I needed to recalculate the offset required between the box and slave cylinder to get the release being in the correct place. We did notice the bearing was about knackered but were far to excited to wait to get a new one.
    Spaced the cylinder forward by 18mm using a few hexagon spacers then got ready to bleed it up. First pump of the pedal......big puddle of fluid on the floor.

    Took the box back off, and the seal had pushed out of the back of the cylinder. Turns out these cylinders need something solid to push on. Major thing carelessly overlooked! At that point i remembered that the release bearing kit cam with a spacer, I couldn't remember whether I binned it or not. After a bit of routing around I found it in a box of brake pads!



    That fitted perfectly, and once reassembled the clutch bled up great. Cobbled the display in with some temporary wiring to set it up and that was about it.
    Ran it up on the ramp and everything works great.



    Had it out the last couple of night and love it, its completely transformer the car. I will Get a video uploaded at some point.
    Downside is the release bearing is completely shot now. I have another one on its way today so the box will need to come off, again! If anyone is running the Burtons type release bearing kit, the release bearing is from a Saab and you can get it from your local motor factors. LUK part number 500033320.

    Next on the list......

    Laser cut bracket to mount the gear indicator off the dash
    Get the hardware installed for flatshift, there are a couple of options available by the sounds of it
    Get the engine and flatshift mapped
    Billet lever incorporating bike brake lever instead of the lift up collar

    The old 5 speed straight cut Tran-x box will be for sale if anyone is interested. I have been meaning to start a for sale thread for months with various bits I have left, I will get around to it!

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  11. #330
    Spanner Monkey Turbosport Subscriber Jimmythedimmy's Avatar

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    Re: Mk2 Duratec Escort

    Awesome, car is truly a credit to you sir!

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  13. #331
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    Re: Mk2 Duratec Escort

    Nice one ! Fantastic job, it makes it all worth while once these projects are all bolted together and you can blast them down the road!

    Is that gearlever a Camillus Bradley extra long jobbie?

  14. #332
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Mk2 Duratec Escort

    Looks great Mark, the car definitely deserves it. The bellhousing looks like it was cast for a standard Ford release bearing anyway so you wouldn't have been able to use your Titan one. I think your only option with your direct lever is a load cell and a geartronics control box to feed your 9A4 with the signal. I've got some photos of when I did Paul Alexander's Grp4 fabs lever. Let me know if you want the pics mate, drop me a text or something.

  15. #333
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by Paul C View Post
    Is that gearlever a Camillus Bradley extra long jobbie?
    Hi Paul, the lever is a proper Quaife long lever with short throw tower. The lock collar is a bit crap though, going to bin it and go for a V brake lever, sure I have some spares in my shed!


    Quote Originally Posted by cossie matt View Post
    I think your only option with your direct lever is a load cell and a geartronics control box to feed your 9A4 with the signal. I've got some photos of when I did Paul Alexander's Grp4 fabs lever. Let me know if you want the pics mate, drop me a text or something.
    Thanks Matt, as always, any info would be greatly appreciated. I had a quick look at the Geartronics module but that is about it. Tom did say you would be the man to ask!

    Got the brackets on the laser yesterday. Will get this on the car tonight. Also going to change that release bearing



    Next priority. Getting it log booked and go rallying. Still need, 1 new seat, 2 new harnesses, plumbed in extinguisher, proper battery, spares, intercom, helmet, race suit and much more

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    Mk2 Duratec Escort

    Well, new release bearing has not cured the problem even though the old one was shot.

    If the car is in neutral, clutch not pressed, rattles like a ba***rd. press the clutch and its as quiet as I would expect.

    Can only think of 2 things, clutch fingers or clutch needs shimming up.

    Has anyone got any thoughts on what if could be?

    ​enquiries@flintec-eng.co.uk

  17. #335
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    Re: Mk2 Duratec Escort

    Just got the display mounted on the dash......


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  18. #336
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    Re: Mk2 Duratec Escort

    Car is looking nice, must be awesome with that box in it,

    What cluch plate you using? is it a twin plated clutch?

  19. #337
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    Re: Mk2 Duratec Escort

    Hi I'm just fitting a hydraulic clutch... Iv had a measure up and the gap between the bearing and pressure plate is 32mm. How much free play should I allow between them? Would I be ok going for a 30mm spacer leaving 2mm between them?

    Cheers

  20. #338
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    Mk2 Duratec Escort

    I will pass on the advise I was given, worked perfectly for me.
    Put the clutch housing on with no plates in, the fingers will then be extended out as far as they will go, measure from the back of the motor (where the bell housing seats) to the furthest point on the fingers.

    This is the position your release bearing wants to be when its home, so its the same dimension from the bell housing face to the release bearing.

    Think my dimension was 78mm but it depends on your set up.

    Is that any use? I can do a cad model if it helps

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  21. #339
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    Re: Mk2 Duratec Escort

    Yes that's spot on! I didn't think of removing the plates. Iv done a measure up with the plates in there and allowed for 2mm clearances. Will check your way!

    Thanks

  22. #340
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    Re: Mk2 Duratec Escort

    Just read all this thread. Absolute quality. Nice one

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  24. #341
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    great build. Have you considered selling the rocker covers they look amasing

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  26. #342
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    Re: Mk2 Duratec Escort

    Its nearly a year since i last updated this ............

    Car has been absolutely great up to a couple of months ago. Its never really been used in anger since finishing it (which turns out to be a good thing), and has barely covered 1000 road miles.
    Whoever prepped the shell must have decided against welding the link boxes in properly They were the 2 piece ones which look to have split down the joint between the 2 pieces and the the front half, which was then taking all the load from the link bars started tearing out of the shell. Nice!

    So it was a heartbreaking couple of days cutting the old ones out and dressing up the shell ready for welding new one piece heavy duty ones in...........



    You can see in the image below where the prop flange has been hitting the floor when the link boxes moved


    Also made 2 of these gussets to weld inside the car from the front of the link box (behind the seat, to the floor under the seat, to strengthen it all up further.



    ...........got here valeted to make me feel better about chopping it up



    Other biggest issue to date has been the failing of the mechanical thermostat during a set up session on the rollers. This was only highlighted, luckily, because the the mapping software flagged up high temperature. I had no mechanical gauge fitted. So I have added a mechanical gauge reading temperature from the water rail. That got me thinking about the position of the thermostat, and I dont think its in the correct place in the system (between the rad outlet and the engine.) The Raceline water rails have thermostat located within the rail its self, pre radiator which is a much better place. So rather than buying a new water rail I have bought and fitted an inline stat which came from Canada, into the top hose. I will get a photo of that tonight.

    Took the car testing to Teesside Autodrome last month. Great day, Great to finally test the limits of it, far exceeds expectation. Took some X22 Dunlops but it was far too warm for them so ran most of the day on the Toyo Proxies and it still astonishes me how well it sticks to the road. Things learnt.....need some harder compound 13" tyres, needs stiffening up on the rear possibly an anti roll bar and need some better brake fluid, brake pedal hit the floor whilst flat in 6th after about 20 minutes of hard driving.



    GoPro vid of the last run of the day on the road tyres



    Next up.........I have my forms for my MSA licence, just need to book the BARS test
    I project for the winter is to build a new engine for it, the head will be going off for machining in the next few weeks. I think i will need to gear the car longer with a new CWP once the motor is finished.
    And flatshit to install.

    ​enquiries@flintec-eng.co.uk

  27. #343
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    Re: Mk2 Duratec Escort

    your car is so fast, beautiful job and it seems amazing, congratulations.

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  29. #344
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    Re: Mk2 Duratec Escort

    Nice car would you be interested in doing another cam cover as that looks the goods

  30. #345
    Racer Decade Plus User mexicotait's Avatar

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    Re: Mk2 Duratec Escort

    Glad to see you back mark
    Hope all is well with work etc

    Will you still be producing parts
    Im after some seat side rails and a few other bit soon
    Hexham and District Motorclub

  31. #346
    Pit Crew Decade Plus User cossie matt's Avatar
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    Re: Mk2 Duratec Escort

    My link boxes did the same Mark the two piece ones are meant to be the better ones but we've both found different. I also went for the gusset route and did the lower section too under the floorpan to the chassis rail.

    Car looks great, I've got a nice 307bhp you can buy?!��

  32. #347
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    Re: Mk2 Duratec Escort

    Quote Originally Posted by mexicotait View Post
    Glad to see you back mark
    Hope all is well with work etc

    Will you still be producing parts
    Im after some seat side rails and a few other bit soon
    Work is crazy, not sure where the last year has gone. I need to commit some more time to getting the car ready to rally and using the thing!
    In terms of parts, I can still produce most parts, seat rails are simple enough to do give me a shout when you know what you need.


    Quote Originally Posted by cossie matt View Post
    My link boxes did the same Mark the two piece ones are meant to be the better ones but we've both found different. I also went for the gusset route and did the lower section too under the floorpan to the chassis rail.

    Car looks great, I've got a nice 307bhp you can buy?!��
    Thanks Matt. I can believe the 2 piece are as good as the one piece ones, but i suppose either are only as good at the guy welding them in. Drop me a message about your motor

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  33. #348
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    Re: Mk2 Duratec Escort

    love the vid and the car

  34. #349
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    Re: Mk2 Duratec Escort

    Awesome vid. Car pulls well

  35. #350
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    Re: Mk2 Duratec Escort

    Great to see the car in action after all the build thread! Thanks for posting

  36. #351
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    Re: Mk2 Duratec Escort

    Using the Christmas break as a chance to get a few bit done on the car, first big job is to get the oil cooler mounted up. Drawn the brackets up today. Just waiting on the rubber mounts being delivered in the new year


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  37. #352
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    Re: Mk2 Duratec Escort

    Every time I see that cam cover I want one!!
    If you want to make another I'm ready to pay

  38. #353
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    Re: Mk2 Duratec Escort

    It is on the job list Moisty. The plan is to rapid prototype a pattern then have some sand cast and machined. It will happen, eventually !

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  40. #354
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    Re: Mk2 Duratec Escort

    What about getting some water cut
    Thats what we have done with some bda ones
    Hexham and District Motorclub

  41. #355
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    Re: Mk2 Duratec Escort

    The BDA ones are pretty much flat, because the cams sit so proud on a Duratec the overall height is about 70mm from memory, then in need machining out

    ​enquiries@flintec-eng.co.uk

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    Re: Mk2 Duratec Escort

    Hiya. Great thread and good tips!!
    Would you do me a rocker cover. It's awesome!!
    let me know !!
    thanks👌👍👍

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    Re: Mk2 Duratec Escort

    What a cool build. I want one of those rocker covers!!

  44. #358
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    Re: Mk2 Duratec Escort

    Very nice!

    Looks good with them black wheels

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    Re: Mk2 Duratec Escort

    Quote Originally Posted by flinny1986 View Post
    brake/clutch cylinder reservoir bracket
    Attachment 48401

    Whilst browsing, I really like your reservoir bracket. How much to make me one please?
    Sorry I can't seem to get the photo up.
    Last edited by rallyrob; 12-01-2017 at 13:07.

  46. #360
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    Re: Mk2 Duratec Escort

    Such a rapid Escort.

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