My mk2 Rally car - Duratec power

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  • JonSegger
    Mechanic
    • Jan 2004
    • 520

    Re: My mk2 Rally car - Duratec power

    I haven't updated this thread for ages - mostly because we haven't spent much time on/in the car. We didn't get to do the Lynn Stages in October as the event was cancelled. Although, as it turned out, we wouldn't have got to do it anyway as my second daughter was born on the day the rally would have taken place. The new baby has taken up quite a bit of time since then and that, in conjunction with not having as much 'spare' cash nowadays, has meant things have been a bit quiet car-wise.

    Anyway, 11th Feb 2012 saw Mark and I competing in the South Downs Stages at Goodwood. Just like every time we've done it before, it was a very cold day. The oil temp gauge read -7.4 degrees centigrade when I started the car!

    We got through scrutineering without any issues and then it was time for the first stage. I felt pretty rusty if I'm honest - not having driven the car for a while, so I was pleasantly surprised that we were 12th fastest on the first stage. The second stage felt better and we were 7th quickest.

    It all went wrong on the third stage though. Some of the chicances were marked out with lorry tyres and as I went through one of them it I just clipped one of the tyres with my right front wheel. It whipped the steering wheel out of my hands and as I grabbed it again to re-join the circuit, I could see that I'd done some damage as my steering wheel was now perfectly upside-down. The yellow tape marker was now at the bottom. The car would still going in a straight-ish line, although I could feel that something wasn't right. We finished the stage taking it a little easier through the rest of the chicanes and then inspected the damage when we got back to the service area.

    The wheels were now toe-ing out somewhat and upon closer inspection we could see that the brackets on the crossmember that hold the steering rack were bent up and partly torn. There was nothing we could do to fix them, so we carried on for the rest of the day as it was, checking the rack mounts after each stage to make sure that the damage wasn't getting any worse. I had to be a bit more cautious for the rest of the day though as we couldn't afford to hit it again in case it pulled the rack off completely.

    The last two stages were in the dark, which was great fun. We finished the day 13th overall and 6th in class. Not brilliant, but better than a DNF which it could have so easily been.

    Here's a couple of photos:






    So, this weekend I got round to repairing the damage to the steering. I had to cut one of the brackets off the crossmember and make a new one. I also had to repair the locating bracket that is welded onto the tube of the rack itself. I think the pictures show what I mean better than words:














    Comment

    • cossie matt
      Mechanic
      • Sep 2005
      • 983

      Re: My mk2 Rally car - Duratec power

      Sounds like it was a cold cold day at Goodwood mate, I bet you didn't have any oil temp probs there like some of the events we have done together!!!

      You must have given the rack a fair old clout, that's a fairly bent mount there!!! When I got my cross member, before I got it powdercoated I boxed them all in with extra bracing. Mind you with a knock like that it'd probably just bend a steering arm instead Glad you got to carry on and finish anyway. Cross member looks good as new again

      Laura and I have got our first baby due in 10 days so I think I will just have to be happy with polishing mine for a little while At least she's all ready to go in the garage.

      Hope to see you around soon mate.

      Matt
      sigpic

      Comment

      • JonSegger
        Mechanic
        • Jan 2004
        • 520

        Re: My mk2 Rally car - Duratec power

        Hi Matt,

        Yes, oil temp was fine, but water temp was a bit of a worry. I'm running a thermostat in the water system now because I was concerned that the water temp wouldn't get high enough (which happened once before at Goodwood in the freezing cold). With the thermostat it was fine when we were moving, although it was getting too hot whilst we were queueing for ages waiting for the starts. I couldn't turn the engine off whilst we were waiting as the battery was knackered and wouldn't start again without a jump start. I have a new battery to fit now though.

        Good luck with the impending parenthood! It's hard work, but very rewarding at the same time. The months just fly by and before you know it they're not a baby any more, so enjoy it while you can. The car will still be there in a few months time

        Comment

        • JonSegger
          Mechanic
          • Jan 2004
          • 520

          Re: My mk2 Rally car - Duratec power

          So 'time flies' and all that... about 6 years in this case!

          I still have the Escort. We've not done much in the way of rallying for a few years though. One reason for this was that the MSA introduced rules regarding seats and belts having expiry dates. These went out of date for my car, meaning I needed to replace them if I wanted to continue competing. I just couldn't justify the cost at the time, given that we were only doing one or two rallies a year. It seems wrong to spend all that money and then only use them maybe 10 times if I'm lucky. The MSA then introduced a requirement for HANS devices, which also means new crash helmets. It was all too much, so we just used it for a few track days instead. A lot cheaper and still lots of fun.

          As the car has seen a bit of action, it was showing its age a bit. It's a very solid shell, but there was a rust patch on both of the door posts (the only bits I didn't cut out and do properly when I built the car) along with some damage to the rear quarter. I also had fitted a roof vent which just didn't work properly because it sat too far back and the airflow skipped over the top of it. I couldn't sit it any further forward because the internals hit the roll cage. I'd added a dodgy extension to the front of the air scoop, which worked better, but looked a bit crap.

          So it was time for a freshen up. The main objectives were to give it a fresh coat of paint, fix the rust/damage and fit a better roof vent. So about a year ago the mini-rebuild began...

          First job, getting the stickers off (which took ages) and then sorting the door posts:
















          New roof vent fitted:








          Off for the respray at Scole Engineering:










          Back home, looking fresh:
















          It's taking shape now. Hoping to crack on some more over the next week or two.

          Comment

          • mexicotait
            Racer
            Decade Plus User
            • Oct 2008
            • 2437

            Re: My mk2 Rally car - Duratec power

            Looks very nice Jon

            I’m in the same boat as you although I built mine so I could still use is for road rallying glad I did now as I will never see the stages with how much it costs now although most of the targas etc I have done have been just as much fun at a fraction of the cost
            Last edited by mexicotait; 12-02-2018, 18:32.
            Hexham and District Motorclub

            Comment

            • JonSegger
              Mechanic
              • Jan 2004
              • 520

              Re: My mk2 Rally car - Duratec power

              Originally posted by mexicotait
              Looks very nice Jon

              I’m in the same boat as you although I built mine so I could still use is for road rallying glad I did now as I will never see the stages with how much it costs now although most of the targas etc I have done have been just as much fun at a fraction of the cost
              Cheers. Yes, it is a shame, but as you say, targas and road rallies, along with track days and sprints etc. are all good fun too. Less regulation and cost can't be a bad thing...

              Comment

              • GavinR
                Pit Crew
                Decade Plus User
                • Jun 2004
                • 1494

                Re: My mk2 Rally car - Duratec power

                Hi Jon,

                Good to see you've still got the Escort and she's getting some attention
                I'm sure there are a lot of people in the same position - with a good car but needing to spend thousands on updating to new safety regs

                Gavin
                GavinR

                sigpic

                Comment

                • scoobymike
                  Bodger
                  • Oct 2014
                  • 176

                  I cannot believe anyone using EBC pads on rally car .or quick road car come to think. Just asking for trouble

                  Sent from my SM-N9005 using Tapatalk

                  Comment

                  • JonSegger
                    Mechanic
                    • Jan 2004
                    • 520

                    Re: My mk2 Rally car - Duratec power

                    Originally posted by GavinR
                    Hi Jon,

                    Good to see you've still got the Escort and she's getting some attention
                    I'm sure there are a lot of people in the same position - with a good car but needing to spend thousands on updating to new safety regs

                    Gavin
                    Hi Gavin,

                    Yes, I'm sure there must have been a drop in the number of clubman level competitors, which is a shame. Good to see you're still competing and doing well though!

                    Comment

                    • JonSegger
                      Mechanic
                      • Jan 2004
                      • 520

                      Re: My mk2 Rally car - Duratec power

                      Just by way of a quick and long overdue update - I've still got this car. Still not been out competing in it, for reasons mentioned previously, but we have done a few track days. This is what it looks like now:

                      Click image for larger version

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                      Comment

                      • mexicotait
                        Racer
                        Decade Plus User
                        • Oct 2008
                        • 2437

                        Re: My mk2 Rally car - Duratec power

                        Looks very nice mate
                        Hexham and District Motorclub

                        Comment

                        • JonSegger
                          Mechanic
                          • Jan 2004
                          • 520

                          Re: My mk2 Rally car - Duratec power

                          And just to keep this thread alive, here is a couple of videos from the last track evening we did at Snetterton:




                          Comment

                          • rallyrob
                            Racer
                            Decade Plus User
                            Turbosport Subscriber
                            • Apr 2010
                            • 2726

                            Re: My mk2 Rally car - Duratec power

                            Very nice indeed.

                            What diff ratio does the car run?

                            Comment

                            • JonSegger
                              Mechanic
                              • Jan 2004
                              • 520

                              Re: My mk2 Rally car - Duratec power

                              Originally posted by rallyrob
                              Very nice indeed.

                              What diff ratio does the car run?
                              Cheers.

                              It's a 4.6 now. (It was originally a 5.1, but that was too low geared.) It's on 15" wheels at the moment too, which gears it up a little for the long Snetterton straights.

                              Comment

                              • rallyrob
                                Racer
                                Decade Plus User
                                Turbosport Subscriber
                                • Apr 2010
                                • 2726

                                Re: My mk2 Rally car - Duratec power

                                Originally posted by JonSegger
                                Cheers.

                                It's a 4.6 now. (It was originally a 5.1, but that was too low geared.) It's on 15" wheels at the moment too, which gears it up a little for the long Snetterton straights.
                                Okay, thanks. What does it rev to about 7500-8000rpm?

                                Comment

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