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Thread: Road Rally Mk2 Escort No 5

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    Bodger

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    Road Rally Mk2 Escort No 5

    Hello all, I am in the process of building my fifth road rally Escort. The last one was 30 years ago .....but time never dulled my enthusiasm for the modelled the sport.
    This is the motor.... bought in Holland about 5 years ago and driven back to Ireland .Attachment 88716

    Hopefully I intend to take part in Endurance Trials and Multi venue auto tests here in Southern Ireland, Targas rallies in Northern Ireland and I would really love to do some road rallies in Wales. I would consider doing some historic stuff in the future but for now the car will have power steering and a 5 speed box....so not allowed in that category.

    Here's the dirty work starting...stripping the underseal .. I bought a roll over jig which made life much easier.
    Attachment 88717

    This is Escort no 3 on The Highwayman Road Rally 1992 with Tim Sturla. Photo by kind permission Andy Manston.
    Click image for larger version Name:	TURBOSPORT 6.jpg Views:	212 Size:	89.9 KB ID:	88719

    No 5 is actually ready for paint now so in the coming days/weeks I will post photos of progress together with a few photos of Escorts No1 to No4....back in the day.
    Attached Thumbnails Attached Thumbnails TURBOSPORT 2.jpg‎  


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    World Champion Decade Plus User alladdin's Avatar

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    Re: Road Rally Mk2 Escort No 5

    nice to see it all

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    Re: Road Rally Mk2 Escort No 5

    Look forward to it

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    Re: Road Rally Mk2 Escort No 5

    The shell was blasted and the welding repairs and strengthening done. I didn't do the welding myself as a local expert was doing such a good job I would have only devalued the car. The shell was quite good to start with...it needed new sills, splash panels, both boot wells, some repairs to rear arches and a right hand drive dash. The car was seam welded, strengthened and skidded. ....then dry built.
    Repackable Tony Law back box modded and bolted up
    Attachment 88743
    Engine in
    Attachment 88744
    historic type gusset
    Attachment 88745
    These are Escort MK3 RS1600i sets made by Steele, retrimmed in a material similar to beta cloth.
    Attachment 88746

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    Re: Road Rally Mk2 Escort No 5

    This is Escort No2 ...New Cedos Rally 1989...Dave Howe navigating pic by Andy Manston
    Click image for larger version Name:	ESCORT NO2 NEW CEDOS 89 ISH.jpg Views:	183 Size:	139.6 KB ID:	88747

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    Re: Road Rally Mk2 Escort No 5

    Here's the underneath showing panhard rod tower, skid plates, tramp brackets, turrets for exhaust, 2 new boot wells and lower rear panel trimmed/shaped.
    Click image for larger version Name:	ESCORT UNDERNEATH.jpg Views:	158 Size:	121.9 KB ID:	88748

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    Re: Road Rally Mk2 Escort No 5

    The Scheel seats (not Steele as I said in an earlier post) had to have their bases modified and plates welded to the floor. The plates on the side of the auto tunnel are for historic removable seat bars should I wish to install competition seats.
    The gearstick has been moved to accommodate type 9 5 speed/type E 4 speed gearboxes, the base for a hydraulic handbrake has been strengthened, the tabs on the tunnel are to hold the rear loom and brake line. The electric fire extinguisher bottle will be positioned behind a navigator's foot rest.
    Click image for larger version Name:	ESCORT INTERIOR 2.jpg Views:	166 Size:	124.8 KB ID:	88749

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    Re: Road Rally Mk2 Escort No 5

    Attachment 88781
    Here is Escort No 4 sitting in my parents drive in Dollis Hill, North West London. I bought the car off Mike Brown who has just won the Colway 1300cc rally series in it...circa 1993. I converted it to road rally spec. ie: took the stickers off, put in my 1700 x/flow lump with 34 DGAS carb, back seat and carpet and it was ready to go. I only did a couple of road rallies in it...and the gave up.
    Attachment 88782
    Back to No5. Here it is being blasted for the second time.

    Spec of No5:
    Vulcan Engine
    205 bloc 2060 cc
    Cast pistons
    Standard rods
    Tracsport alloy sump
    Lightened flywheel, Helix clutch
    Wasp starter
    Maxiflow 3 head
    FR30 cam
    Ashley 421 2 inch exhaust
    Dave Brooks split 45's carbon air box

    Tracsport 5 speed type 9 gearbox 2.48/1.61/1.225/1:1/0.82, single piece prop

    Narrow semi floating atlas built by Andy from Arrow Engineering, 4.6 LSD

    Rs2000 spec brakes but vented fronts/rear drums, bias pedal box, braided lines

    Loom by Beagle Automotive, Racetec gauges,

    Alloy fuel tank, twin pumps, braided lines

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    Re: Road Rally Mk2 Escort No 5

    Just to add to my last post my shell is currently being painted......I have all the bits ready here to build it up.

    I missed the suspension info:
    Bilstein group 1. front 260/60 inserts 190 llb 10 inch springs, roller top mounts, alloy hubs, World Cup x/member cranked steering arms and twin cam anti roll bar, 2.4 quick rack and power steering byPower Steering Solutions
    rear bilstein, single leaf decambered...not sure poundage , off 1300 auto, 90/100 llb? I didn't want 146 llb which seems to be the only offering wherever you go.

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    Racer Decade Plus User mexicotait's Avatar

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    Re: Road Rally Mk2 Escort No 5

    Looking forward to seeing this getting built.
    Hexham and District Motorclub

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    Re: Road Rally Mk2 Escort No 5

    After blasting and epoxy priming the underneath was given a good coat of Mipa protector....its similar to Raptor I'm told.
    Click image for larger version Name:	TURBOSPORT 1.jpg Views:	119 Size:	111.5 KB ID:	88822

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    Re: Road Rally Mk2 Escort No 5

    Here's the shell loaded up and heading for paint.
    Click image for larger version Name:	shell off for paint.jpg Views:	118 Size:	99.8 KB ID:	88823

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    Re: Road Rally Mk2 Escort No 5

    Happy days

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    Re: Road Rally Mk2 Escort No 5

    Click image for larger version Name:	shell home.jpg Views:	103 Size:	134.5 KB ID:	88862
    The shell is now home ......I have most of the components here for building it and am realistically looking to have it running by next March.

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    Re: Road Rally Mk2 Escort No 5

    Sorry for lack of updates...its been one step forward two steps back. I stripped the axle (except pinion) as I didn't like the rusty look after it had been standing for year and a half ...so got it blasted...got a specialist to reset the pinion and then hand painted the casing. The tramp bar brackets were double skinned and a breather put on the diff cover plate as the original breather hole was were the tramp bracket wanted to go.
    I made a mistake by taking out the firewall after the dry build ....we learn! I sealed the rear firewall with fireproof sealer....but can somebody tell how does a scutineer know that the sealer is actually fireproof?
    Anyway the painter decided not to seal inside the boot before because I "didn't tell him to". Anyway I decided to continue on with my new sealing skills to the boot area with the fireproof sealer......another mistake as it has silicon in it and you can't paint over it. To cut a long story short I re-sealer the whole area of the boot and hand painted it...I was dreading the what the boot was going to look like but it turned out alright thankfully. At last I got that area sorted ..next up engine/gearbox in......now I'm stuck again. The rear of the gearbox is touching the tunnel ...see photo. I have a World Cup crossmember/brackets from Group 4 Fabrications. What is the done thing here? I'm thinking drop the engine cross member and elongate the 4 holes to straighten things up? Any advice here appreciated.
    Attached Thumbnails Attached Thumbnails gearbox touching.jpg‎  


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    Re: Road Rally Mk2 Escort No 5

    Axle painted...drum brakes retained incase I decide to do historic events
    Click image for larger version Name:	axle car.jpg Views:	81 Size:	99.3 KB ID:	89068

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    Re: Road Rally Mk2 Escort No 5

    Axle painted...drum brakes retained incase I decide to do historic events
    Attachment 89068

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    Re: Road Rally Mk2 Escort No 5

    W.r.t. the engine crossmember: I wouldn't elongate the holes.
    You could fit a crossmember chassis tube kit or (what I did) modify the engine mounts in such a way that the engine + gearbox fit the tunnel.
    Click image for larger version Name:	ebay-pics-095.jpg Views:	76 Size:	51.7 KB ID:	89069

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    Re: Road Rally Mk2 Escort No 5

    Thanks Miniliteman....I have that chassis tube kit fitted . Good call about the engine brackets...I will do that

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    Re: Road Rally Mk2 Escort No 5

    Quote Originally Posted by JimKeogh View Post
    ....we learn! I sealed the rear firewall with fireproof sealer....but can somebody tell how does a scutineer know that the sealer is actually fireproof?
    ..
    Speaking as a scrutineer, they will only be looking to see there are no gaps that fluid can pass through, they wont actually check to see if its fireproof

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    Re: Road Rally Mk2 Escort No 5

    Thanks Graham.
    Just to follow up on an earlier post I got the gearbox moved over and now its about 3 mm from the tunnel...I'll leave it at that for now and see how it behaves when I drive the car.
    The fire extinguisher I went to great pains to position behind the navigator's footrest is not legal here in Ireland for stage rallying. I'm going to put it behind the drivers seat and move the battery from there to the boot. The oil cooler had to be moved as well as the pipes were not long enough. So much for my dry build!

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    Re: Road Rally Mk2 Escort No 5

    The boot is nearly there..just a couple of earth straps to bolt in
    Click image for larger version Name:	escort boot.jpg Views:	39 Size:	116.2 KB ID:	89084

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    Re: Road Rally Mk2 Escort No 5

    Looking good

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    Re: Road Rally Mk2 Escort No 5

    A photo here of the interior. I had to cut up the mint carpet and there will be a bit more cutting when I get the roll cage back from paint. I was at Group 4 Fabrications today in Galway returning the M16 callipers vented discs and spacer kit as they didn't fit. They are genuine Ford reconditioned calipers and for now there is a a lot of head scratching going on.
    Click image for larger version Name:	escort interior.jpg Views:	33 Size:	143.2 KB ID:	89085

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    Re: Road Rally Mk2 Escort No 5

    Too nice to rally…don’t do it!

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    Re: Road Rally Mk2 Escort No 5

    ...its only going to be used for a bit of fun....I'm not chasing pots.........for now!
    Quote Originally Posted by FrankC View Post
    Too nice to rally…don’t do it!

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    Re: Road Rally Mk2 Escort No 5

    ...its only going to be used for a bit of fun....I'm not chasing pots.........for now!
    Quote Originally Posted by FrankC View Post
    Too nice to rally…don’t do it!

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    Re: Road Rally Mk2 Escort No 5

    here in Belgium, extinguisher must be accessible by both from their seat and needs to be a 2kg one.
    Last edited by Mkdu; 27-03-2024 at 13:45.

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    Re: Road Rally Mk2 Escort No 5

    Yes I have a hand held one which will go just infront of the navigator's seat
    Quote Originally Posted by Mkdu View Post
    here in Belgium, extinguisher must be accessible by both from their seat and needs to be a 2kg one.

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