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Thread: Escort mk1 - xflow to XE to Cossie!

  1. #481
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Well even the IAW datalogger didn't show anything interesting - just that the revs drop off to 400rpm or so when the problem occurs. It does show that the temperature and everything else is well within what they should be, so that's positive, I guess.

    Still have an odd 'hiccup' with the engine when it gets up to temperature. Also seems to happen when you rev and then close the throttle - the revs will often drop back to below idle.

    Revs dropping:


    Almost stalls after revving:


    It's loads better than it was, but it's just not right. Probably time to let someone more knowledgeable than me take a look.

  2. #482
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Bonnet on, but need to get it fitting a bit better. It's catching on one side - I think the new bonnet rubbers need altering a bit.

    Also the new bonnet cable seems to a bit too longer on the inner cable - it's not fully releasing the bonnet catch. Will have to try and take up some of the 'slack' somehow.

    P1080395-.JPG

    P1080396-.JPG

  3. #483
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    Re: Escort mk1 - xflow to XE to Cossie!

    My old 911 targa..used to have a similar problem..would run erattic /not start /stall if under 1/4 tank of fuel...turned out the old pump was knackered and couldnt pull the fuel through....i dont think its your problem...but if your running that low on fuel could be hunting for fuel...cheers mark

  4. #484
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Spoke to Motorsport Developments recently - we're going to run it with the lambda disconnected for now and up the CO mixture to 2.5% and run it in open loop mode to get it on the road and tested. Hopefully get that done by mid-August.

  5. #485
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Bonnet cable keeps on stretching when I use it:

    P1080398-.JPG

    Cable doesn't feel too tight, but the lever needs enough of a pull that it's starting to actually pull out the coiled solid inner core of the cable where it fits over the clevis pin (there should be 2 complete coils in the photo - you can see where one has been pulled out).

    Going to try taking the inner cable out and just run a throttle cable inner instead and loop the ends over... see if that handles it any better.

  6. #486
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Bonnet finally on:

    P1080417-.JPG

    P1080418-.JPG

    P1080419-.JPG

    Changed the cable to just a normal braided throttle cable and it works spot on. Needed a little adjustment on the bonnet catch itself, but it's closing nicely now; gaps are looking good as well.

    Just the new Ford lettering to put back on and then it's all done from the outside.

    I've got a small leak on the fuel filter in the boot, as well as a sump plug washer to replace as it's weeping slightly, other than that I think it's a case of getting a few test drives done before I take it to get an MOT. I'll get the CO% checked at the same time and then give it a bit of a shakedown before booking it in to have it checked on the rollers and tuned properly and find out what is really up with the fuelling, lambda sensor and those other running issues.

  7. #487
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Got the fuel leak sorted today, as well as fitting the bonnet lettering, so from a mechanical/bodywork perspective the car is now finished.

    Of course, that's not the end of the story.

    I had my first 'road trial' of the car.... well, by road trial I mean drive along the street and back

    The good news is the car feels absolutely rock solid - it tracks straight, it's not wanting to pull to one side or the other, in the cabin there isn't a load of rattles or vibration and the road noise is substantially less than it used to be (that'll be the insulation working as intended!).

    Less good points are that the clutch has a really low biting point, so it's really on/off at the moment, and the engine really wants to stall all the time; it's still not sorted. The brakes are also dreadful. As in you would stop faster if you opened the door and stuck a foot out. So there's something really wrong there.

    Biggest problem though, was an awful banging coming from the diff area. So we got the car back on the lift and had a look:

    P1080424-.JPG

    Areas where the prop has been hitting bodywork circled above in yellow.... and below is the corner of the bracket where it's been catching:

    P1080423-.JPG

    We've got Cosworth calipers and a disc conversion on the rear, and to get it to work you need to have a second bracket for the cable, since it's not a single pull system. The problem is that the deflection of the prop under suspension movement was causing it to hit the newly fitted bracket. Bummer. This mean we spent most of the afternoon coming up with an alternative, and this is what we did:

    P1080425-.JPG

    P1080426-.JPG

    Handbrake action still feels nice and there's enough slack in the outer cable for no nasty angles anywhere. Didn't get another chance to run the car again, but hopefully that should cure that one problem

    Next up to re-check the brakes and revisit the idling/running problems; hopefully with a pre-check at my dads mates who run an MOT testing station.

    Finally as proof the car now runs under its own power



    Last edited by MegatronUK; 20-08-2017 at 18:45.

  8. #488
    Racer Decade Plus User wildo105e's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    great stuff, a few teething issues but nothing that seems impossible. well done

  9. #489
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Attempted to sort out the brakes today - even in 'crap running' mode its worth having brakes that actually slow you down. I may as well have brake pads made of cheese right now.

    So after having bled all of the brakes again (despite having a really firm pedal anyway that didn't pump up) I started looking at the pedal box, the threaded adjuster bar didn't seem to be moving right, and getting a closer look showed it wildly skewed out of alignment - I'm fairly sure it was so far out of alignment that one or other of the master cylinder pushrods has been binding and not giving me full travel. It was also making a nasty noise as the bar attempted to work its way loose:



    After thinking long and hard about it, the only way to know for sure was to take the pedal box out.

    Once it was out it was clear that the alignment of the clevis pins on the threaded bar to keep them inline with the master cylinders gave too much side to side movement of the spherical bearing, making one side move wildly out of alignment as the bush could then deflect the bar massively as the pedal was pushed.
    We decided to pack the space either side of the bearing and the clevis pins with fairly thick washers to allow them to retain some movement, but cut down the excessive movement that was causing the pushrods to bind.

    Here's a close up:
    P1080428-.JPG

    The action is now working like this - the (drivers) left cylinder being the front one, so we have it adjusted currently to come on marginally before the rear cylinder which is the (drivers) right:


    Of course, now the whole lot needs to be refitted to test properly. That's going to be a job one evening, but I'd had enough for one day.

    Testing out my new phone so I also got a couple more running videos - the first one it sounds sweet, but still has that odd idle issue; it drops momentarily at 0:20 and 0:52 seconds:


    Here's an even weirder one. Running lovely then all of a sudden it just stalls, just suddenly:


    If I can get the brakes sorted, then the clutch adjusted to a point where it's not like a on/off switch, I'm prepared to overlook the running problems so that I can get a couple of miles on it and take it to someone to check it over properly.
    Last edited by MegatronUK; 27-08-2017 at 19:10.

  10. #490
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    Re: Escort mk1 - xflow to XE to Cossie!

    nice mk1 project

  11. #491
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Still on with the last bits of tweaking - been sorting out the clutch pedal travel (clutch has been working only at the last 10-15mm of travel) though it may still need a new cover plate at some point, and another round of bleeding the brakes (definitely better with the re-set pedal box, but needs some more work). Everything seems to work now (bar the ongoing engine gremlims), it's really just making sure it's okay to take for an MOT. Maybe this week or next.

    Sorted out a bit of an issue that kept appearing with the throttle cable jamming from time to time - the plastic grommet that comes through the bulkhead needed trimming back a little. Also the few short road tests I've done showed that in 1st and 3rd gear the gear lever hit the front of the gear surround, so we opened up the hole a little, now it clears. One of the reversing lamps also worked intermittently, looks like it is the one with the corrosion that I did the vinegar bath with. May have to bypass the original bulb holder at some point, but since the reversing lamps aren't MOT tested, it's more for my sake than anything else.

    Other than those few little niggles, it should be ready for an MOT right about now.

    Also took the opportunity to take a few photos with the car outside. No photoshopping, just a crop and resize:

    IMG_20171105_a.jpg

    IMG_20171105_b.jpg

    IMG_20171105_c.jpg

    IMG_20171105_d.jpg

    IMG_20171105_d-.jpg

  12. #492
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Just a quick update to say that I'm not any further with the car. I ordered a new clutch cover about a fortnight ago (Helix heavy duty) as even with the cable tightened right up the clutch was really binary on/off, no feathering at all. I'm still waiting for it, so the car isn't going anywhere at the moment

    Was hoping to get it tested and over to someone local I've found with Cossie knowledge to sort out the running issues and get it set up properly, but it doesn't look like that is going to happen anytime before Christmas.

  13. #493
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Finally got the replacement clutch cover sorted, also did a few other bits and bobs this weekend which I've been putting off - replaced the rear gearbox oil seal and got a more permanent fix for the vacuum line from the inlet manifold to the servos.

    Clutch action is much better - biting point is around half way up now, rather than just a fraction off the floor. It should drive a little easier now.

    With that in mind, we'll try and get it on the road and tested in a couple of days.

  14. #494
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    Re: Escort mk1 - xflow to XE to Cossie!

    Insane project m8!

    Keep at it. There is light at the end of the tunnel

  15. #495
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Getting on for nearly 18 months since I last touched the car. Didn't get much done last year as I was quite ill for most of it.

    Anyway, going to try and get it off the sorn and tested asap. It's running reasonably, but still needs a good tunr. Biggest problem is still the clutch... It's horrible. Biting point is virtually on the floor, so it wants to stall all the time (even reversing in and out of the garage is a pain, never mind trying to drive it properly). I have a feeling that the pedal arm simply isn't pulling enough of the cable to actuate the T5 clutch. Going to try and extend the pedal arm this weekend (and move the securing pin for the cable further towards the end of the pedal arm) to see if that will do anything to help... If not, then it may be looking at a hydraulic conversion.
    Last edited by MegatronUK; 18-09-2019 at 23:05.

  16. #496
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    Re: Escort mk1 - xflow to XE to Cossie!

    The hydraulic clutch conversion is fantastic, very easy on the leg and very smooth. I went hydraulic after talking to a few escort people complaining about the heavy pedal subsequently bending pedals and snapping cables. It was a no brainer for my mk1 cortina cossy conversion.

  17. #497
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Escort mk1 - xflow to XE to Cossie!

    Quote Originally Posted by Colr6 View Post
    The hydraulic clutch conversion is fantastic, very easy on the leg and very smooth. I went hydraulic after talking to a few escort people complaining about the heavy pedal subsequently bending pedals and snapping cables. It was a no brainer for my mk1 cortina cossy conversion.
    If I wasn't so close to finishing and just wanting to get it done, I think that would be what I'd be doing. As it is, I'd have to undo quite a bit of work to fit another master cylinder, remove the bracing for the power steering, fit another fluid container, etc, etc. It's always something I can do later.... but hindsight is always 20:20

    That aside, this is the sequence of pedal modifications that we came up with today:

    IMG_20190920_152326-.jpg

    That, you could say, was mk1..... and of course it didn't work. Total amount of extra cable pull at the gearbox end... perhaps 5mm, even though it was a good 15mm or so at the pedal end at the highest point (which of course was like trying to squeeze a housebrick!).

    So for mk2, we tried something different....

    IMG_20190920_165651-.jpg

    The cable attachment point is moved closer to the fulcrum of the pedal and now travel up and over the metal bearing. So instead of a straight cable pull it pulls in an arc; more cable pulled for the same amount of pedal pressed. Unfortunately this one also didn't work... because the metal bearing was too bulky and fouled on the pedal box mounting bolts as well as the pedal stop on the back of the pedal box. However, the idea was sound, so we then tried a smaller bearing....

    Here's mk3 with a smaller bearing and a slightly lower mounting for the bearing itself:

    IMG_20190920_172454-.jpg

    Result? Pedal is superb. Biting point is about half way through the travel, rather than being virtually on the floor. It's a heavy-ish pedal for sure, but the action is really nice.
    The one issue is that we've taken up all of the slack in the cable - including taking off both nuts and the gearbox sleeve to get it onto the clutch arm. It's tight!

    We did try a mk4 with a smaller bearing, to free up a bit of cable:

    IMG_20190920_181103-.jpg

    Alas, still not enough cable freed up, and the smaller bearing doesn't give enough leverage; the biting point drops virtually all the way back to the floor again.

    I'll try to get a slightly longer clutch cable made up, but with the mk3 pedal (once it has been suitably strengthened and painted!) it can at least now be driven! I'm going to try to get some time over the weekend to sort out some last niggles with the ISCV solenoid valve (a new replacement and, surprise surprise, it doesn't work at all - all modern units have completely wrong spring rates, as they're not for the Cossie), but other than that, I think we're good to finally get rid of the SORN that has sat on it for the last 15 years or so and get it tested this coming week

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