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Thread: Mk1 Escort (Ratspeed) project build....

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    Re: Mk1 Escort (Ratspeed) project build....

    Pics of the steering rack....its not finished..but finished enough for fitting and making sure it works......











    Because i have to keep the cross member(racing rules) i need to modify it to allow room for the new rack..

    The plan is to move the centre cection to point backwards...if you no what i mean...
    A quick test by bolting the cross member on backwards gives me the room i need...



    Remove it cut out the middle turn the middle and weld back together....







    Ok all done ...now to check rack clearance...for sump and engine bracket and make a steering rack mount...









    i pressed a new bush in the cross member and checked sreering arm clearance...the arm clears but the standard steering coupler will hit...
    but because of the new angle of the rack arm i need to make a new steering joints to suite (and clear the exhaust...

    checked my suspension at fully closed and i have 1" ground clearance...which is good ..





    .it has a clearance issue on full left lock on offside.(i relise this probly wont occor in real life) but nows the time to create the clearance needed...



    I tried a standard bmw steering joint to see if there was more clearance than my rose joint...and i was surprised that there was not even enough to fit the wheel on...so rose joint it is...



    Thats all for now...

    Next job is to see if a rx8 ally radiator will fit...

    cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    Huikeeta and that means awesome times ten. It took some time to read this project. Well you are not making the easiest project. I like your way of doing things. I will be waching this project indeed.
    Last edited by Deluxe66; 16-12-2017 at 22:59.

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by Deluxe66 View Post
    Huikeeta and that means awesome times ten. It took some time to read this project. Well you are not making the easiest project. I like your way of doing things. I will be waching this project indeed.
    ...cool..thanks mark..

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    Re: Mk1 Escort (Ratspeed) project build....

    Don't know how many times I have read through this.

    Crazy, and total inspiring.

    What rules are you building this to?

    Do you think it may be getting a bit heavy, not being negative here just wondering if you have a target weight or something.

    keep the updates coming it's very interesting.

    Cheers

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by Norfolkandgoode View Post
    Don't know how many times I have read through this.

    Crazy, and total inspiring.

    What rules are you building this to?

    Do you think it may be getting a bit heavy, not being negative here just wondering if you have a target weight or something.

    keep the updates coming it's very interesting.

    Cheers
    Im building it to quaffe motorsport news group E...
    yes there is a minimum weight....

    The problem is budget....lighter stuff is way out of my price...

    I always look at using the lightest material...but most times the thickness required to keep the same strength makes the part to bulky...and needs cnc milling to keep strength and make lighter...and i dont have a mill ...so i add weight and loose weight elsewhere......

    I decided to build first...then later i could look at improvements...as im sure it will need many....

    Cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    didnt do much fabrication...but wanted to start to build the side exhaust/sill cover...but before i can do this i need to see how much space is available..
    and this means mocking up the radiator..as you can imagine i want to use a moosive radiator bigger than the standard space..because ive tubed the front i can go wider and by tilting the rad i can go full depth...

    Something like this..



    so i fitted the front panel jig i made earlier in the thread..



    clamped a front panel to the jig




    it fits...then span the front panel to create the basic air scoop.



    i chose a rad from a rx8...they are massive and cheap...its a nice looking rad with all the bells and whistles...





    ok it fits...and i can see how much room for the manifold to snake past...

    Cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    You are a nutter!

    Love it.

    Matt

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    Re: Mk1 Escort (Ratspeed) project build....

    So back to the steering rack...time to make the brackets to fix to the cross member...

    Measured where i wanted the rack to sit in relation to the crossmember...(which is in relation to my bumpsteer ect)

    Clamped in position and made the brackets...i just copied the sierra crossmember fixing method ..except i flipped it over...

    pics of the events...(cant find them....f~~~~~###) hang on ....

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    Re: Mk1 Escort (Ratspeed) project build....

    Ok found them...











    then made the lower bracket










    Checked the rack fitted ..and cleared the cross member and wasnt lower than the crossmember...and that when the engine mount is fitted it missed that....all good so far







    Removed the rack ..and pressed the mounting bush in then fitted the crossmember to the car...




    still fits ...next re-fit the rack and fit a block to check all clearances....

    then remove and give it a grind and a coat of paint...

    cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    nice work bro .....loving those welds ,what machine are you using?

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    Re: Mk1 Escort (Ratspeed) project build....

    Your skills are just insane, i remember reading this before when it was in the very early stages, its come a long way since i last looked.

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    Re: Mk1 Escort (Ratspeed) project build....

    Thanks mate...the welder is an old murex 180...i converted it to euro torch...added a gas solonoid and use c02 fire extinguishers for gas...works for me...
    cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by 5tox View Post
    Your skills are just insane, i remember reading this before when it was in the very early stages, its come a long way since i last looked.
    Thanks ..still a long way to go..but im having fun so its ok...cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    i used c02 pub gas for years and still do for general stuff but for this sort of work i really recommend argoshield light or similar, the weld is night and day - worth the cost and i am always "on a tight budget " (tight git)

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by alladdin View Post
    i used c02 pub gas for years and still do for general stuff but for this sort of work i really recommend argoshield light or similar, the weld is night and day - worth the cost and i am always "on a tight budget " (tight git)
    I never considered the gas would make a difference...always blamed myself for not taking my time...lol...i will give it a go...cheers alladin...

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    Re: Mk1 Escort (Ratspeed) project build....

    i read that c02 "drops the ark" which is why you get the stuttering effect when welding ( and dont notice so much on higher power settings), with argoshield it just keeps a much smoother burn. if you have'nt tried it your in for a pleasant surprise trust me.
    adams gas for one do a small bottle for around £120 with cheaper refills once you have the bottle.

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by alladdin View Post
    i read that c02 "drops the ark" which is why you get the stuttering effect when welding ( and dont notice so much on higher power settings), with argoshield it just keeps a much smoother burn. if you have'nt tried it your in for a pleasant surprise trust me.
    adams gas for one do a small bottle for around £120 with cheaper refills once you have the bottle.
    Cheers mate...i was given a few of them little bottle gas for the hobby welder...just put them in the cupboard..will whack one on the welder tomorrow and give it a go..(prob 10 mins worth of gas lol)...looking forward to trying it out...appreciate the nod....cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    Now i have a cross member i can dummy fit the engine....

    If you remember i will need to rotate the engine a few degrees to allow clearance for the velocity stacks

    So i created a simple measuring jig to check angle of rotation and rotated the engine untill i got the clearance i wanted...





    so you can see the amount i rotated the engine...because i rotated on one engine mount it moved the engine side ways a few cm...so i will need to add some more clearance on the bulkhead lip...here..



    i cut the offending part away...will cut more clearance and box in later when engine removed...



    Happy with positon i modded the engine mount...you can see how much i raised this side ...



    plenty of clearance on the strut top inner wing now...



    While the engine is in position i took some measurements for the exhaust manifold...i want it to go a different route to the normal...forward and then rearward in the wing and ending in a side pipe...

    the space...



    And the route....very ruff idea..



    Ive worked out the sizing i want to use...now got to try and buid it...

    Sorry about the diag..its just for me to get the lengths and diameters when i build it...




    I am going to use stainless steel for the manifold....ive borrowed a tig welder...and ordered some argon gas and some 308 rods...now to learn to tig weld..

    Cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    That's gonna look awesome mate

    I'm thinking of going the side exit route too

    Great work as always

    Matt

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    Re: Mk1 Escort (Ratspeed) project build....

    This may help you in build of manifold?

    https://www.conelayout.com/

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by Matt75 View Post
    That's gonna look awesome mate

    I'm thinking of going the side exit route too

    Great work as always

    Matt
    You have to go side exit...its a zakspeed......yours is looking well cool....cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by Norfolkandgoode View Post
    This may help you in build of manifold?

    https://www.conelayout.com/
    Thanks mate could come in handy...cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    So started to make the exhaust manifold...
    First i made a jig for the head...this will allow me to turn(rotate) the exhaust prinaries and get angle and length correct and fit in the gap ect...

    Of course i didnt have any tube the correct size so i had to make some..









    Then welded them to a scrap head...(who needs a manifold lol)..if you hit them with a hammer they just break of...no penetration on the cast iron..



    I was lucky and have a lot of stainless bends to chose from...the biggest problem is cutting them...

    I wanted to expand the first half of the primaries to fit the second half and create a sliding joint...

    So i found one of these pipe expanders...which as you all no do not work..(they can only expand rubber bands)..so i thought id try and modify it and adapt it to fit my hydraulic hole punch...all it needed was a bolt...

    all adapted and the first try....







    well i managed to expand the pipe 0.7mm...before the bolt stretched and snapped (that was a 10.9 bolt)...
    Tried again ..but this time i put a slot in the tube....managed to expand it more ...but the top had sheared in half...3 of the fingers bent ...one snapped the end of ...and the bolt sheared again....the end result was a square tube....

    So threw it and the idea in the bin ..

    Plan 2 ..made some adapter sleves ..easy worked a treat...

    So after a day of cutting...measuring and re cutting measuring ...starting again... i got pretty much what a wanted...

    To check lengths i sealed one end with tape...and filled with water....if they all hold the same amount of water and they are all the same diameter they must be the same length....

    There is only one point where the exhaust can exit...above the wheel(at highest /lowest travel and under the wing...gives me a window of +/- 5mm..
    ..i put the wing on to check we were under the bonnet also...
    heres the pics..

    its just tacked together at the moment....as im sure ill change it a bit next time...but for today it good...























    next tig welding...cheers mark...

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    Re: Mk1 Escort (Ratspeed) project build....

    Amazing as always mate

    looking the business!!

    Matt

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by Matt75 View Post
    Amazing as always mate

    looking the business!!

    Matt
    Thanks mate...trying to catch you up...

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    Re: Mk1 Escort (Ratspeed) project build....

    Lol, you might actually.

    Haven't even looked at it for 2 weeks!!

    Love the exhaust!!

    Keep it up

    Matt

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    Re: Mk1 Escort (Ratspeed) project build....

    Looking good, What diameters and length or was it in a previous post?

    Shaun

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by escortinadriver View Post
    Looking good, What diameters and length or was it in a previous post?

    Shaun
    Here it is again...



    remember this is a 2.2 pinto...so a bit larger than usual pipe diameters...cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    Nice. defo a bit busy in there but looks to fit ok, I take it engine is going on solid mounts.

    Have you used a donor manifold? Type?

    What about heat on tyre, strut, brakes etc.

    Keep it going mate Quality

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by Norfolkandgoode View Post
    Nice. defo a bit busy in there but looks to fit ok, I take it engine is going on solid mounts.

    Have you used a donor manifold? Type?

    What about heat on tyre, strut, brakes etc.

    Keep it going mate Quality
    I decided against solid mounts and have gone with world cup mounts...but i will probably put some more damping on the upper engine to control amount of movement...ive only got about 30mm clearance on both sides...(exhaust and velocity stacks)

    Ive got some manifold flanges..they are mild steel ..got of e bay for a fiver...cheaper than buying the raw material..ive yet to match them to the exhaust ports...when thats done ill make the anti reversion tubes to match then whack the lot together...??

    Heat is a big issue every where...i plan to duct/box all the seperate heat producers( exhaust...radiator,,,oil cooler ect) to try and keep the under bonnet temp down...

    The exhaust will be ceramic coated...(my mate owns a ceramic coating company so i will get the system coated ) should keep the heat in the exhaust and promote flow...

    The wing and bonnet will be heat protected and vented to allow heat out....

    Thats the plan.....cheers mark
    Last edited by madragon199; 16-02-2018 at 11:29.

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    Re: Mk1 Escort (Ratspeed) project build....

    Heres the flanges...they are actually well made.....bit thicker than i would have used...but will do the job...



    Cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    So the plan today...set up the tig welder...learn to tig weld...and tig the exhaust....

    Had to get the proper gas ..pure argon....then had to get some new gauges...connected all together..no adapter to conect the gauge to the tig...so f#cked around for an hour trying to find something...eventually got a thread and a barb of an accetoline torch that fitted...so connected all up ....turned the tig on and spent another hour trying different settings///..set up some test pieces and had a go...f'#ck me ..its not easy...spent 3 hours melting pipes blowing holes...i got really good at getting the weld rod on the tungsten electrode ...f#ck...eventually after 4 hours i managed to fuse the two pipes together with a kind of nice looking weld...but still couldnt get the filler rod to look like a pile of dimes...mine looked like a pile of shit....so in the end i blamed the tools...lol...big respect to Tig welders ..its harder than it looks......will carry on sunday with a new plan...

    no pics ....cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    This is a great read mark , your doing a cracking job. As for the tig I had the same issues for ages before realising I had the set on AC instead of Dc setting . Or was it dc instead of ac drrr
    The difference was mega.

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by skandimike View Post
    This is a great read mark , your doing a cracking job. As for the tig I had the same issues for ages before realising I had the set on AC instead of Dc setting . Or was it dc instead of ac drrr
    The difference was mega.
    Ihope its a simple fix...i will keep trying untill i get the hang...cheers mark

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    Mk1 Escort (Ratspeed) project build....

    Ac for aluminium Iím teaching myself tig ally
    Itís all got b super clean and fresh sharpened tungsten end
    Get a pedal to alter current as u weld far easier
    Tig steel first on dc to get the practice
    Takes ages to perfect :-)


    Sent from my iPhone using Tapatalk

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    Re: Mk1 Escort (Ratspeed) project build....

    [QUOTE=Ianbavs;3332428]Ac for aluminium I’m teaching myself tig ally
    It’s all got b super clean and fresh sharpened tungsten end
    Get a pedal to alter current as u weld far easier
    Tig steel first on dc to get the practice
    Takes ages to perfect :-)

    Yea..just trying to weld stainless but joints...on dc....as ive learnt its a steep learning curve...just working out how to hold a torch that bloody swivels...was fun...then trying to feed the wire in....and trying to actually see where im going....will have another go on sunday....fingers crossed...cheers mark

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    Re: Mk1 Escort (Ratspeed) project build....

    Amps and clean tungstens is a must for tig...is def a art but if you persist and are quiet patience you will get it, I got a magnifier lenses for my auto lid and it helped me no end - you got to get up as close as poss when tigging it really helps and a man with your fabbing skills I can't see it taking you to long

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    Re: Mk1 Escort (Ratspeed) project build....

    Quote Originally Posted by Peanut1 View Post
    Amps and clean tungstens is a must for tig...is def a art but if you persist and are quiet patience you will get it, I got a magnifier lenses for my auto lid and it helped me no end - you got to get up as close as poss when tigging it really helps and a man with your fabbing skills I can't see it taking you to long
    I hope i get the hang...The gas cost more than the welder.....

    As ive learnt ther are no short cuts...ive had a look a the magnifier lens and ive got one on order.. .also i used mig gloves which were way to bulky..and no gloves was way to hot ...so got some proper gloves on order...also charged my battery drill up ready for cleaning the tungsten...so fingers crossed sunday will be a better day...

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