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Thread: 5tox mk1 escort restoration project

  1. #281
    Pit Crew 5tox's Avatar

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    5tox mk1 escort restoration project

    Quote Originally Posted by runoutofrigos View Post
    I can't help thinking that this little "shelf" you have created here is going to be a haven for all the shit off the back wheels to collect and cause a water trap leading to it rotting out again much quicker than it should...

    The fabrication in general looks superb though.

    Simon
    Yeah i did also think this but it will be waxoyled etc and ill take extra care to keep it nice and clean.
    The lip was necessary to add strength because i chopped out the original bits which stiffened up the bottom of the rear quarter.
    Im also considering mud flaps 😉

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    Last edited by 5tox; 15-12-2018 at 21:00.

  2. #282
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    5tox mk1 escort restoration project

    I bought a 6 point cage for next to nothing but it had come from a mk2 stock car and had clearly taken a bang mishaping it slightly.
    I have shortened the width as it was a squeeze past the b pillars and straightened it up so its nice and symetrical, still got work to do on the c pillars, but now im looking at the cage and cant decide if i should weld the cross back in or not, really cant decide which i prefer.
    Its a road car and more for the look i want as opposed to safety.

    Do you prefer the cross or without?


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  3. #283
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    Re: 5tox mk1 escort restoration project

    I like the look of the cross brace.

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    Re: 5tox mk1 escort restoration project

    Quote Originally Posted by dt36 View Post
    I like the look of the cross brace.
    I second that..

  5. #285
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    5tox mk1 escort restoration project

    Ta, i think i agree. Will glue it back in later this week.
    The horizontal bar across the bottom will give a good mounting point for harnesses too

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    Racer Decade Plus User wildo105e's Avatar

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    5tox mk1 escort restoration project

    Quote Originally Posted by rallyrob View Post
    I second that..
    I third that.

    Progressing well now. 👍


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  7. #287
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    5tox mk1 escort restoration project

    Done loads more work but doesnt look much in the pics, the b and c pillar bars are done, brackets all fabricated and welded on.
    Should have the cross back in tomorrow hopefully.

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  8. #288
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    5tox mk1 escort restoration project

    Made up a few more sections and welded them in, some sections needed very tricky shapes grinding into the end so they butted up nicely.

    did you spot my mistake?
    The short cross bar i welded in is approx 2mm smaller in diameter then the long cross bar... hardily noticable but ill have to cut it out and do it again or itll drive me mad.
    The only other piece i have in that diameter is in my jig so ill have to chop a piece out and graft in another piece

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    Re: 5tox mk1 escort restoration project

    Not been on here for ages but that looks like a good car fella well done ��

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  11. #290
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    Re: 5tox mk1 escort restoration project

    Some good skills there.

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  13. #291
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    5tox mk1 escort restoration project

    Sorted, now just got to prime it so it doesnt go rusty

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    5tox mk1 escort restoration project

    Havent updated in a while, been finishing off some odd bits.
    Both rear wheel tubs completed, Both 4 link boxes are fully seam welded in, sills have been stich welded to the floor pan, centre chassis rails have been stitch welded to the floor... loads of other little bits done including cutting out crap repairs by the previous owner and rectifying



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  16. #293
    Pit Crew 5tox's Avatar

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    5tox mk1 escort restoration project

    Chopped a section out giving more clearance for the watts cover

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  17. #294
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    5tox mk1 escort restoration project

    I managed to pick up a fairly good boot lid at a reasonable price so started messing about with my old boot lid and aero catches to see if it will work.

    In terms of the boot not popping open down bumpy roads plus the extra security of lockable aero catches do you think its a worthwhile modification?
    I already have them on the bonnet and they will be colour coded.

    Ill need to create a bracket for the pin but as per the pics you can see it comes quite a way into the boot area




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  18. #295
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    5tox mk1 escort restoration project

    Ive been thinking on this and i reckon im just gonna stick with the original boot lock

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    Re: 5tox mk1 escort restoration project

    I wouldn't bother with pins personally...

  20. #297
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    5tox mk1 escort restoration project

    Watts towers are on so my baby atlas is now fully 6 linked.

    But im scratching my head wondering what offset wheels i need.
    I have measured 140mm from the face of the hub/disc to the edge of the inner lip on the bubble.

    Do my drawings look correct? Im just a diy enthusiast and have no real idea 😁

    My measurements are using an 8" wheel as an example, the deepest offset ive seen on ebay is -12... do they go any deeper?

    Id prefer 7's if they were available in a mega deep offset


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    Re: 5tox mk1 escort restoration project

    Motorsport Tools have detailed measurements listed with their wheels.

    I know Revolution have numerous offsets, I personally chose Minilite but the powder coating is very disappointing, a wheel nut fell on the rim when taking off and it chipped, plus, even though the fitter was as careful as he could, I have marks on the rim of two wheels. Must be very soft material or something not right.

  22. #299
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    Re: 5tox mk1 escort restoration project

    i quite like the revolutions, been told that the jbw wheels aren't very strong and crack so will avoid.
    haven't really seen many genuine minilites

  23. #300
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    Re: 5tox mk1 escort restoration project

    I haven't updated in a while, i really started cracking on with this again and the 6 link set up is pretty much finished now, just need to purchase an LSD and get my axle built up.

    After spending all that time building a 2.0 duratec i decided to fit a 2.3 so bought a mazda 6 sport donor car which had only done 70 odd thousand, when stripping down i found hardily any wear at all on any of the moving components.
    So the VVT head is being replaced with a 2.3 duratec head which is have tickled in the right places with the dremel (just a clean up really as they already flow well)
    The Balance shaft has also been removed, the oil pickup pipe and sump are from an american ford ranger, i wanted to keep the high capacity 2.3 oil pump which meant heating up and bending the pickup pipe to match the angle of the face (they bolt straight onto the standard 2.0 pump)

    I have a very expensive list of required engine parts so now its a case of just chipping away at that list each pay day.

    ... oh i bought a mazda mx5 NC 6 speed gearbox the other day too

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  24. #301
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    5tox mk1 escort restoration project

    Made up an engine mount today, the 2.3 block is taller than the 2.0.
    Theres approx 2mm gap between the sump and steering rack (which i have already lowered)
    About 20mm gap between the filler cap and bonnet.
    With 2mm gap between the sump bowl and cross member i have about 4mm between my super narrow custom made water rail and the bulkhead.



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  26. #302
    Racer Decade Plus User wildo105e's Avatar

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    Re: 5tox mk1 escort restoration project

    More great progress

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  28. #303
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    5tox mk1 escort restoration project

    I chopped out my gearbox tunnel today as it needed widening to accommodate my bell housing and bolted up my MX5 6 speed gearbox, as i suspected it needs to be raised up about 3"
    Unfortunately the prop tunnel is also too low.

    Im not sure at this stage if ill add some steel to make them fit or just buy the tunnels again and start from scratch.



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    Re: 5tox mk1 escort restoration project

    that 6 speed is a big old gearbox.

  30. #305
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    Re: 5tox mk1 escort restoration project

    its huge and about 45kg, it feels like i spent all of today undoing yesterdays work but i now have the prop end of the gearbox sitting more than an inch lower, the engine is also slightly lower and tilted backwards ever so slightly.

    im far happier with all of the clearances now and the box seems to be sitting where i want it.

    fitted some £60 rear brake discs today which are listed as 'fitting with the bolt on brackets and cosworth calipers', well they still don't fit... the saga continues. in all honestly i think the ally bolt on brackets are crap and need throwing in the bin

  31. #306
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    5tox mk1 escort restoration project

    Nearly finished my gearbox mount, just a bolt hole to drill and a tidy up.
    Had the engine and box bolted in earlier without axle stands, feels like a real achievement

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  32. #307
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    5tox mk1 escort restoration project

    Finished the gearbox mount, much stiffer now

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  33. #308
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    5tox mk1 escort restoration project

    Today i made up a little panel which raises the gearbox tunnel slighly and will accommodate my gear gaitor.
    Initially i was worried the gearbox sat too high but its a nice position and height when sat in the drivers seat.
    Just a few more plates and the gearbox tunnel will be all welded up.

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    Re: 5tox mk1 escort restoration project

    Nice work Sox.

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    5tox mk1 escort restoration project

    Had a go at fitting my handbrake setup this afternoon, it looks ok to me and appears to work but before i go fully welding up my brackets can anybody see anything that needs addressing?

    Its a mk5 escort rs2000 cable which is apparently identical to sierra only a little shorter

    I literally had a few google images to go off, im assuming that the 'loose' sections of cable are held to the body with 'p' clips

    The half moon looking thing is very wide for my prop tunnel so i may need to shorten its width a bit.







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    Last edited by 5tox; 16-08-2019 at 17:14.

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    Re: 5tox mk1 escort restoration project

    Not that I think it will make much of any difference at all anyway, but I'd weld the brackets to the sidewalls of the tunnel rather than to the roof of the tunnel. Original brackets were welded to the sidewalls rather than the roof.

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  40. #312
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    5tox mk1 escort restoration project

    Ta mate, initially i was going to weld to the sides but looked much neater on top, also gave a little more clearance for the prop.

    Admittedly im still a little concerned theres adequate clearance wont know until i have my escort / mazda frankenstein prop made

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    5tox mk1 escort restoration project

    I made up smaller half moon puller as it may rattle when hand brake released against the tunnel
    I’m running carbon prop it’s close but ok depends how low ur car sits :-)


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  43. #314
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    5tox mk1 escort restoration project

    I think im going to chop the ends off the short cable and extend it about 10cm removing the cable and welding in a piece of solid bar,
    This will mean that my half moon and brackets are about 10cm further back within the diff tunnel where theres more room

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    Racer Decade Plus User wildo105e's Avatar

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    Re: 5tox mk1 escort restoration project

    good to see the brakes sorted. Hopefully dropping my casing off today to get the diff installed.

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  46. #316
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    5tox mk1 escort restoration project

    I decided i would let somebody build up my axle / diff too, apparently its very easy to get it wrong leading to pemature wear.

    Well i have welded in my length of bar and im much happier having all the half moon and brackets in the diff tunnel.

    Please if you see anything wrong shout up, im no mechanic, just a DIY hobby.

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    Racer Decade Plus User wildo105e's Avatar

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    5tox mk1 escort restoration project

    Quote Originally Posted by 5tox View Post

    Well i have welded in my length of bar and im much happier having all the half moon and brackets in the diff tunnel.


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    I was going to suggest a flat bar with a 90 Deg twist in it and a hole at each end.




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  48. #318
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    5tox mk1 escort restoration project

    The idea of a hydraulic handbrake on a road car is ridiculous but it makes me smile every time i look at it.... such a big kid

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    Re: 5tox mk1 escort restoration project

    "Please if you see anything wrong shout up, im no mechanic, just a DIY hobby."

    Sox, think you put your self down incorrectly there, DIY yes, but you've turned out some quality work with attention to detail.

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  51. #320
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    Re: 5tox mk1 escort restoration project

    Quote Originally Posted by 5tox View Post
    I decided i would let somebody build up my axle / diff too, apparently its very easy to get it wrong leading to pemature wear.

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    I'm the same there doesn't seem too much info shared out with setting up diffs. To adjust them correctly you need to use shims behind the bearings but you need to remove the bearings to change them and they are a press fit. It wasn't worth the hassle even though i like to try.

    I took mine to RACE in stoke as they are about the nearest i knew and their reputation is without question. Met Phil today who showed about 5 fully floating axles ready to ship, they looked the business.
    Last edited by wildo105e; 17-08-2019 at 19:00.

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