Canadian Mk1 Escort YB Turbo Rally

[formulaphoto]

As you may know, Escorts are few and far between over here in North America. So, when a rally friend posted his project for sale I jumped on it. I'd been eager to get my hands on a RWD rally car for a while...never thought it would be an Escort though!

I've spent the past few weeks pouring over the car, making lists, and figuring out where to take the project. As with any hand-me-down project car, there are things I'm excited about, and things I'm not so happy with. But overall, this car has all the right bits and should be a lot of fun when it's complete. I'll document the progress here.

First off, the basics...



1971 Escort, imported as a standard street car from the UK, and then work commenced by the previous owner to install the cage and modifications to install the YB Turbo. It came with a lot of shiny nice bits...AP tarmac brake kit, fuel cell, Bilstein coilovers, 5-link rear setup, Tilton pedal box, T5, YB Motor, couple sets of wheels... On the flip side, it has been cut up a bit for the fuel cell and they decided to chop the bulkhead to move the motor back. Great for balance, not so much for aesthetics :P



The first big task after buying it was, of course, getting it home. And when the seller is 4500km clear on the other side of Canada in the middle of winter, this was a bit of a logistics hurdle. Instead of flying back home from the final Canadian Rally Championship event (where I am the TV Producer), we rented a uHaul and drove it back. Four days later, and it was tucked away in my garage!


Loading up in Ontario


Heading across the Prairies


Home in the garage with its new friend, my housemate's VW Beetle Salzburg replica. In good company!

I'll post more as we go along...this week we've already made some big changes so I'll get the story caught up soon!


Ernie leads the way, 4500km across Canada

[Liam_LET]

will keep eye on this one

[formulaphoto]

A few photos of the car as I started pulling it apart for further inspection and analysis!

Location of the motor...quite a lot of space up front! But that will soon get re-filled with a new radiator and intercooler.



Turbo: Should be "fun" trying to route the exhaust with the engine pushed so far back. Down pipe will need to turn immediately down from the turbo outlet! Also note the re-routed steering column.


Front struts with eccentric top mounts and cage tie-in. I don't know if the springs are tarmac or gravel rated...what lb springs are most people using for gravel spec?


Tilton pedal box and reservoirs. The reservoirs are going to get moved to the engine bay probably (or a more accessible location in the cockpit).


ATL Fuel cell dropped into the boot floor. Borrowed a shaped fuel tank to test fit. Pretty sure I'm going to get a fuel cell (with bladder/foam) made using this as a pattern.



And finally...today's status: Taking two steps backward to take several leaps forward. To be legal for Canadian rally regs, several bars were added to the Custom Cages cage, including a full X in the main hoop. However, the X wasn't centred, the welds were a bit crap, and it was attached to the rear stays. So, we've cut out the full X, and the diagonals in the main hoop, and will be re-welding in a new X plus some harness bars.
Before:

After:


After waiting over the holidays, I'm hoping my parts shipments from the UK will be dispatched tomorrow! Progress, progress...

[formulaphoto]

Oh yeah...and this arrived recently. 1.5Gal Peterson oil tank to go with the Pace Dry Sump system I've ordered. Seems small, but our calculations seem to say that it will be big enough for the YB system. Anyone have feedback on that?

[turbospud]

i have a 2 gallon tank on mine but is runs with 1.5g in the system,seems to work fine,no oil cooler pipes run under car to boot so lose the heat that way

[formulaphoto]

Making some more headway. The car went over to our local rally shop (Rocket Rally - they run the Subaru Canada factory team) for the cage updates. Still working on a few things, but I'm much happier with the car's safety and rule-conformity now!

In good company...


Gussets in the a-pillar to roof added...


Full X is now in the main hoop as it should be (as opposed to being set back from the plane of the main hoop like it was before) and harness bars added...


Next up is to finish adding some gussets, build a firewall, add compression strut brackets, and build boxes to cover the gearbox shifter and hydraulic clutch slave. I've been pouring over the other projects in the forums trying to decide the best solution for this!

[jimmy2006]

looks good

[formulaphoto]

Have been stalled on the project for a week or so while travelling for work, but spending some time planning out the project. I've been banging my head against the wall a bit trying to decide what to do for the engine. I definitely don't want to run the turbo...and I would like a 200-230hp free revving engine with good torque - it will be a loose surface rally car after all. So, I've basically got a couple of options as far as I can tell:

1. Convert the YB Turbo to NA. I like this idea, as it would keep the same engine mounts, gearbox, bellhousing, etc. but am unsure of how much work and money it will involve, and if that effort is worthwhile in the end? If anyone has done this conversion to NA before and can help me get a better idea of the work involved, I'd greatly appreciate it. Knowing exactly what needs upgrading/changing would be a great start. I've read a few magazine articles but its hard to say what's "nice to have" and what's essential. Anyone have a parts list?

2. Sell the YB and find a rally-tuned Pinto. They use the same block (205) so essentially it should bolt right in to where the YB Turbo sits now, correct? What sort of power numbers can you get from a Pinto in fast road/rally tune? How much do decent Pintos go for in the UK?



Thanks for the help!
W

[Joe-Tait]

Pinto would go straight in and would be the best option for a rally car IMO. NA cosworth is a great engine but is costly to get good power

[Escortfan_111]

Hi!
Good job so far!
I think both engines would be a good. Biggest problem I can see, is to fit in a good intake system (TBs or carbs) with it so far back in the car.

[formulaphoto]

Yeah, I'm going to have to move the engine forward again, for sure. A bit of a shame it was cut in the first place (previous owner did that)...

Hi!
Good job so far!
I think both engines would be a good. Biggest problem I can see, is to fit in a good intake system (TBs or carbs) with it so far back in the car.

[team_zi]

4500 km's towing! Wow, respect.

Looks great, keep the photos coming

[formulaphoto]

Slowly...sloooooowly...making some progress. Pulled the Yb motor a few weeks ago, and I've bought a nicely-built 165hp 2L Pinto with manifold and carbs to replace it for the time being. I think the Yb will be a long term project for when I want more power down the road.


Finally home for more than just a few days, so I'm diving into a few areas. This week I'm pulling the rear end apart to check it all over and re-install it properly, and installing the new brakes. I'm going to the UK in a week's time, so I'm hoping to have a definitive "shopping list" ready so I can bring home any missing or needed parts!

Question about rear axles... I have a pretty standard English rear axle on the car, with a Quaife rear diff in it. The previous owner did all the modifications for the 4-bar and panhard rod. I'm thinking about whether I should be upgrading to semi-floating hubs/axles? After a recent conversation I was left a little worried about the durability and potential for the whole wheel and axle to come sliding out if the bearing fails. Does anyone have some experience with semi-floating English axles?

Would a kit like this be a wise move?
http://www.motorsport-tools.com/quai...t-hub-kit.html

[andy-v]

<man of few words..............nice

[EricE]

Hello fellow Canadian! First rate car! I hope to see you at an event soon. You going to run anything this year?

I know nothing about the atlas axle but I do have a suggestion for you. Perhaps you may want to move away from the ford axle due to the lack of them on this side of the pond. I've seen a few people put toyota axles out of hulixs in escorts on this fourm and I think you would see more of it here but im guessing they are not very common in the uk. However over her we got the toyota 8 inch axle in 4runners and pickups/ tacomas. Im running a 8 inch out of a 4runner in my volvo 240 but can't actually comment on it yet as i've yet to drive the car with it. Something to maybe think about for the future. Good ratio selection, cheap r&p's, cheap diff options (supra diff shimmed for higher break-a-way torque, removable center section, and stout)

[formulaphoto]

Hi EricE,

Yeah, I've debated putting something else in - even a Ford 9" from the various domestic Fords. I'm going to run this English axle until it breaks (or doesn't) because it already has the Quiafe diff in it, and all the welding done for the 4-bar and panhard rod.

Hoping to do Mt. Hood Rally and Big White Rally at the end of the year - we'll see how things go! My goal is to have it ready for shakedown in August.

[formulaphoto]

Slow going, as I haven't been home to make much progress, but putting some hours in this week. Hoping to get the fab work done by the end of the month!

I spent some time in the UK last month, and snuck a day of driver training in at Higgins Rally School. Was great to get some right-hand-drive and RWD seat time! Good motivation to keep up the build progress too.


In the last update I was pulling the turbo motor, and I brought the 2L Pinto home recently. Built by a well-known race engine builder in Portland, and I drove the escort it came out of before I bought it...pulls hard and apparently rated at about 170hp, plus very driveable which is important for my first RWD car!


I kept finding things I wasn't happy with on the car, so I pulled EVERYTHING back to bare shell. This way I also get hands-on experience with every nut and bolt on the car.


Also cut out the rear fuel cell box. It will be replaced with a more traditional cell in the trunk (boot).


I love how light the shell is, even with the cage. Four of us were able to lift it off the stands and shuffle it around the garage (my friend's Audi project is finally running and moved out!).


And here's some fun bits that came in recently...I'm having a good time specc'ing out a minimalist/modern race interior! Summit Technologies Raptor and Talon units for the controls, and a Stack dash.



Hoping to have some more significant updates for this thread soon! I'm itching to get this done.

[MegatronUK]

Must be quite an unusual car to have over there. Can't believe you pulled the Cosworth out in favour of an asthmatic old Pinto though - 170bhp? The Cossie lump will do twice that easily will virtually no internal mods

Any idea if the car had actually been used much before you got it? The reason being that an English axle generally wouldn't last long with the YB lump.

BTW, that steering column routing and those interior fluid cylinders are horrendous Whoever did that should be shot! Glad you're re-doing it!

[formulaphoto]

Well, it's been a long year since I last posted! The car is now on the verge of completion, and will be running it's first rally event in June in Idaho! I'll write a longer build story a bit later, but I with the car making it's first public appearance yesterday at a rally car gathering in Vancouver, I thought I'd post some photos here too! Still many details to finish, and some engineering/fitment issues still to resolve (T5 bellhousing and starter isn't meshing with the pinto flywheel, etc.) but it looks and feels like a car again!

Fitting the glass, and then it was off to the meet-up...



My goal with the interior was "clean an simple" and I'm really happy with how it turned out.




More to come...

[formulaphoto]

Dragging this thread out from the depths... But the car has made it's "debut"! A long time coming, but it's ended up beyond what I ever thought it would be. So much fun to drive too! Mk1 Escort with Ivey Engines 2.0L Pinto, 5 link rear end, Quaife LSD in English axle and a few fun bells and whistles inside.


It just finished a 3-day, 1500km tarmac tour in British Columbia, and I've now got a lengthy list of things to fiddle and tweak, plus the full gravel protection needs installing. First gravel shakedown will be in June or July at Dirtfish Rally School.

[Dan_pita]

Excellent!! Congratulations!!

[wildo105e]

Looks great.

[Erikmex]

Very nice, and makes for a much more driveable rally car than a YB turbo, i visit Oregon alot, my sister lives there, cool to see your Pinto was built in Portland. For gravel, and probably tarmac too, i think a plate type LSD will work much better, Quaiffe diffs allow the inside wheel to spin if you unweight the inside, yopu'll find the car much more driveable on gravel with a LSD that locks.

[dazzle]

I can't believe I've only just seen this!!
I'm a Brit in Calgary and I brought a MK1 Escort across with me.
I only use it for track days at the moment but I love every minute in it

Do you have any plans for Rally's this year? I have a few friends who will be doing the Kananaskis in October and talking about Big white which is over your way in December.

Would be good to see an Escort spanking newer cars

[EricE]

Wow your mk1 turned out great! Giving me motivation to get my poor volvo dusted off and running properly. Planning on running some events in the near future?

Dazzle who do you know running kananaskis?

[dazzle]

Wow your mk1 turned out great! Giving me motivation to get my poor volvo dusted off and running properly. Planning on running some events in the near future?

Dazzle who do you know running kananaskis?

Hi Eric, I see you're Calgary as well!

I have a couple of friends who Rally Subaru's who were talking about the Kananaskis rally

[Pikey15]

Dragging this thread out from the depths... But the car has made it's "debut"! A long time coming, but it's ended up beyond what I ever thought it would be. So much fun to drive too! Mk1 Escort with Ivey Engines 2.0L Pinto, 5 link rear end, Quaife LSD in English axle and a few fun bells and whistles inside.


It just finished a 3-day, 1500km tarmac tour in British Columbia, and I've now got a lengthy list of things to fiddle and tweak, plus the full gravel protection needs installing. First gravel shakedown will be in June or July at Dirtfish Rally School.

Lovely car, well done

[EricE]

Oh wanted to ask if the t5 in the car is standard or did you end up fitting a gear kit of some variety?

Hi Eric, I see you're Calgary as well!

I have a couple of friends who Rally Subaru's who were talking about the Kananaskis rally

Yes I am! Have you enjoyed our lovely october so far haha!? Perhaps a setup for snow is in order for your escort so it can come play on ghost lake this winter! Where in calgary are you and how long ya been on this side of the pond?

[turbospud]

on front top mounts the circlip holding the bearing in should face downwards

[Erikmex]

Well spotted, they’re on upside down, that circlip is under a lot of load, that’s got strut insert through the bonnet written all over it

[dazzle]

Yes I am! Have you enjoyed our lovely october so far haha!? Perhaps a setup for snow is in order for your escort so it can come play on ghost lake this winter! Where in calgary are you and how long ya been on this side of the pond?

Tuesday was interesting to say the least!!!
I did think about that before, maybe 13" studded tires

I work up by the airport but live on the West side.
Been here since August 2012

[EricE]

Ahhh never mind on the welcome front then, your clearly well versed at this point with our ummm... temperamental weather

Would love to see your escort some time. I am also in the west end (montgomery) Studs for the escort would be a recipe for big grins!!! If you want to do them on the cheap keep an eye out at walmart. Years ago they put studdable winters on sale for 35ish cad a peice. They are cheap tires but I fit them with over sized studs and just run them on the lake, and rallies if needed so not terribly concerned. Not sure how easy it is to find 13's around here though. Could you fit a 14 or 15" wheel to it?