Escort Sigma 1600 Race Car

[Roadsport]

Re: Race Escort Zetec SE (engine build)

Few better pics of the cam belt tensioner pulley. And the funny stud that came with it.












I think you get the idea.

[Roadsport]

Re: Race Escort Zetec SE (engine build)

I can take some pix of mine if it will help. I thought the 1.6 and 1.7 were basically the same block and water pump etc.

Have any pics yet?
I've got some doubts still for this Peugeot pulley. It has so little solid surface are against the block (water pump) that I'm a bit worried will it hold. A failure there would be a disaster I'd rather not risk.

[owlscastle]

Re: Race Escort Zetec SE (engine build)

Sorry, havent taken the pix yet, will do this week. Looking at your pix I can see the difference now.

[Roadsport]

Re: Race Escort Zetec SE (engine build)

Sorry, havent taken the pix yet, will do this week. Looking at your pix I can see the difference now.

OK, reat. Thank you!

I received ja tip that Wv Golf mk IV 1.6 16v pulley would do. I'll check in to that too...

[owlscastle]

Re: Race Escort Zetec SE (engine build)

Attached pics of my Puma setup.

I have a spare backplate which might help.

Have you thought about using a BDA belt tensioner, they are being re-manufactured and are qyuite chunky and solid. Available through Wilcox Engines

[Roadsport]

Re: Race Escort Zetec SE (engine build)

That looks like a very reliable system. I especially like the fact that the tensioner pulley bolt tightens to the block rather than to the mounting plate or to a waterpump. That sure looks solid.
I'd have to change my water pump to use that one tough. But that can be done.The blocks are identical. Only the wtr pumps are different and the tensioner set up.
I've now had my waterpump housing surface milled flat to gain more surface area for the puley to push against. And found a more suitable pulley from Audi. This one does not need any studs only the 8mm bolt to tighten it. Or in this case I'm thinking of using stud bolt. This would relieve the allot threads of any stress. And make dure the bolt does not push the waterpump away from the block. This pulley also has a bit larger diameter as a added bonus.

If this set up does not look 100% when put together I'd gladly buy your spare plate. If you'd be willing to sell.
I'm quite frustrated now with this tensioner dilemma taking so much time. I want to install the engine allready

I shold get the bits back from the machine shop today so could take some pic again.

[owlscastle]

Re: Race Escort Zetec SE (engine build)

The pulley doesnt bolt direct to the block but to the plate, which is about 8mm thick. The plate is held to the block by three bolts.

[Roadsport]

Re: Race Escort Zetec SE (engine build)

Did not get the parts today from the machine shop. So I'll have to wait for the weekend to see how these latest inventions work out.

Did however install the modified cros member. The new one felt a lot lighter than the world cup cros member. Did not have the patience to stop and weight them tough.


P.S

The Golf tensioner pulley was automatic one. No good.

[Roadsport]

Re: Race Escort Zetec SE (engine build)

Finally got the tensioner thing sorted.
This one is a Audi tensioner pulley with a fixed spacer in the back. This on is a larger than the original or the XU puley so the belts is so tight to fit I needed to slide the belt to the cam pulley grooves to get it on. Maybe it is an avantage IF the pulley should sometimes come loose. Should'nt come loose tough. The stud was tighten with thread locker, I used a lock washer and a lock nut.







Also needed to pass some time in the garage before running into the night. So I took a litle peek how would the engine look when finally done. The trumpets are'nt there to stay. The real ones are a lot shorter. Looks angry tough.
I'm glad the alternator fits nicely too and did not cause any grief with the throttle bodies.
Putting the engine covers on makes it look a little standard. Not so race engine like. But I think I'll leaver the covers on there for that extra protection. Time will tell how long do have the patience to remove the covers to do the check up in the pit between starts.

[Roadsport]

Re: Race Escort Zetec SE (engine build)

In the third picture above is the water pump milled flat for more surface area and friction for the tensioner pulley.

[Roadsport]

Re: Race Escort Zetec SE (engine build)

The crank case breather blanking plate arrived the other day.
Looks nice to me. I like the little details.
For no particular reason I used the most expensive sealant ever. Costs 1167€ / litre. I borrowed it from work. Obviously.

[Roadsport]

The best fthers day gift ever

Some update on this weekend.
Finally got the timing done.
It is a nightmare to get it right with the lift @ tdc method. Using three dial gauges it took ten hours to get it right. On saturday!
Somewhere during the epic process I decided to measure wheter the Ford engine timing tool would stop the piston preciselly to TDC. And it did. So finally using the timing tool and now only two dial gauges we got the both cams spot on. Within one hudreds of a millimeter from the lift needed @ TDC.
Now that I've got the timing right I really need to do some markings to aid the basic timing next time around.

And I received the best fathers day Gift ever.





Now, on to installing the engine to the car.

[Roadsport]

a step forward again today.

After some tinkering and adjusting the engine found its place in the bay.

Had some clearance issues with the oil lines and the oill filter. The filter was hitting the steering coupling. Wich would not be an issue for you UK fellas. Lucky b******s.
Also the scavenge hose and a inlet pipe were compressed between the engine and syeering rack. Raised the box and the engine about an inch or so. Sorted the issues.
Now I need to manufacture the engine and gearbox mounts.

[david_white]

Re: Race Escort Zetec SE (engine build)

Blimey you're not hanging around now. Engine sits nice in there and will look great once the TBs and exhaust ae bolted on

[Roadsport]

Re: Race Escort Zetec SE (engine build)

Blimey you're not hanging around now. Engine sits nice in there and will look great once the TBs and exhaust ae bolted on

Yes the exhaust. That needs to be done first tough. Damn I need to hurry. But I received the collector for the exhaust manifold on friday. I'll order the flange next week. So after the mounts It'll be the exhaust or the wiring.
Made a promise to some friends of mine that the engine will be smoking before new year.

Of course I was very, very drunk at the time