Escort Sigma 1600 Race Car

[Roadsport]

back in business

It was a twenty hour work day yesterday and drove 800 km's but now It's safely home!!!





My all new military style camoflage uber cams

[Moggy]

Re: Escort

Very nice!

did you change the valve sizes? we run standard inlet and larger exhaust.

[Roadsport]

Re: Escort

Very nice!

did you change the valve sizes? we run standard inlet and larger exhaust.

This one has slightly bigger and longer inlets and outlets.

[Roadsport]

Re: Escort

Some pics of the test build. Measuring the clearence between piston and valve with very scientific blue tack method
Job had to be left unfinished. I had to attend to a house warming party.
But I did some masurements and it seems the clearance is onugh for now. Still have to measure the compression. Ill have to skim the head and check the clearance again.

[Roadsport]

Re: Escort

Still have to measure the compression. Ill have to skim the head and check the clearance again.

If the compression ratio is not as high as I need it to be that is.

[Roadsport]

Re: Escort

Got the plate back from the shop today. And It came out perfect. Now I have a solid base to bolt the engine mount to.
The plate was quite dark and greasy so gave it a quick touch up.

Program is saved to the jet cutter so these can be easily re produced If needed.






Going to give the cam timing a try this weekend. It's not going to be a walk in a park since it has to be done with lift @ TDC method using three dial gauges.
After finding out the space between piston and valves in the TDC i can start calculating the compression ratio. And send the pistons to be coated.

[Roadsport]

Re: Escort

Gave the mounting plate a bit more polish today.
This will do for now. Did not have it anodized because I'm not sure is this right type of alloy for having it done. Maybe I'll give it a go after I've repolished the plate a few times

[Roadsport]

Re: Escort

We got the timing for the test build done today
Plenty (ish) of clearance between the valves and pistons. Now we'll figure out the exact compression ratio. Now I can be confident we can atleast skim the head to get the compression needed.

Some pics of the timing using lift @ TDC method. Had no chance getting the dial gauges to the cylinder no 1 buckets so we had to do the timing with the fourth cylinder TDC.

Firs we set the lift @ TDC using two dial gauges


Then locked the cams in place and lifted the first and fourth pistons to TDC using third dial gauge.





Istalled the betlt and checked the timing.




The tensioner had thrown the timig and lift off by six tenths of a millimeter so we timed it again Thank god (or Kent Cams in this case) for adjustable cam pulleys!
In the end of the day we got as close as two hundreds of a millimeter away from the manufacturers values. Close enough for the test build.

Then I dismantelled the head and measured the blue tack (pic earlyer in this thread) squeesed by the valves. Looks ok. Did not take any pics of the squeesed blue tacks tough.



So on to measuring the compression ratio....

P.S

I'm not too thrilled about his OE timing belt tensioner pulley. We had some premature failures with these ones at work.
Has anyone found a propper replacement? I'll be changin this tensioner to every season so I think it'll hold but still not big fan of automatic spring loaded tensioners.
For example the engine couild not be rotated counter clockwise because the spring would've gave up and the belt would jump. Had to do two whole rotations clockwise every time...

[Roadsport]

Re: Escort

Mesured the air between piston and valve and it seems to be 2mm @ tdc after skimming the head.
Only one tenth of a mm needs to removed from the head. The compression ratio with the skimmed head is 12.8:1 so very pleased with that.


The pistons are sent to be coated this week and the head is at the machine shop. Hope to start the final build up next week.

Oh, and for the final build the OE tensioner pulley will be changed for eccentric metal one.

[Retromotorsport]

Re: Escort

I think, but i may be wrong, that Clint was using Cosworth YB tensioners

[Roadsport]

Re: Escort

I think, but i may be wrong, that Clint was using Cosworth YB tensioners

With the Zetec SE ? I'll have to check into that. I was steered to Audi's way.
Thank you!!

[Retromotorsport]

Re: Escort

Ahh yeah, you not using the 2.0L Zetec.. sorry may be a wrong steer then

[Roadsport]

Re: Escort

Ahh yeah, you not using the 2.0L Zetec.. sorry may be a wrong steer then

Thats right I'm going with the all alloy small block baby Zetec.

Audi tensioner looks right by the looks of it but I'll now for sure when i fit one.

VAG corporation also provides me a radiator I wanted. With the water inlet and outlet on the same end of the radiator. This will make the plumbing a lot more easier for me.

[Roadsport]

Re: Escort

Little garage science. The future cros member taking a acid trip
I mean taking a dip in a citric acid bucket.

Not really sure witch should be negative and witch positive but this way the rust seems to bubble more.





After rust removal I' ll use a spot welder to make the crossmember more rigid. And after a bit of cuting It'll be powder coated.

This way I don't have to ruin the world cup cross member.

[Roadsport]

Re: Escort

Today I started the final build up of the engine.
Got the head back and now its re-cleaned and skimmed down by one tethns of a mm.
Also got my pistons back today. The new coat on them looks quite dood. Got the pistons in the block today.
Hoping to get the head on to the block on weekend.
Then I think I'll have to do the timing again.

And hopefully sometime next week I can start to do the modifications to the crossmember to clear room for the newcommer.

That citric acid worked fine on the old rusty crossmember. Now the other end of it will get dipped.