Escort Sigma 1600 Race Car

[Roadsport]

Re: Escort Sigma 1600 Race Car

I bought my box new and it has leaked since day one. It wasn't rebuilt by Tran-X. I've only tried to have the leaks fixed by some local "specialists". Now having battled it my self it seems to hold its liquire. Had to try three times to get it right though. This SL 72 design is somewhat odd or something has gone wrong when it was assembled. But no point complaining now that the warranty is long gone and the manufacturer is out of business. Anyway now its fixed for the season and I'll know more when I dsmantle the box after the season.
My box gets off easy 200bhp 190Nm 870kg car

[Roadsport]

Re: Escort Sigma 1600 Race Car

Few rather pointless pictures.

Look how dry it is. Not a drop (and yes there is oil in the box)


No leakage here eighter just dry dry dry...




Engine needs to be suspended in order to get the box out


This little thing dropped to the floor once I undid the engine mount bolt.

[exboyracer]

Re: Escort Sigma 1600 Race Car

Good news on the box

Materials used for the engine mount look a bit to thin, was the plate gussetted to the box section either?

[Roadsport]

Re: Escort Sigma 1600 Race Car

Yes and no.
I'm pretty sure the next version will be thicker and gusseted. I believ I got off lucky. Only a tiny mark in the sump. It could have been A LOT worse.

[Roadsport]

Re: Escort Sigma 1600 Race Car

Yes and no.
I'm pretty sure the next version will be thicker and gusseted. I believ I got off lucky. Only a tiny mark in the sump. It could have been A LOT worse.

Well that was not the case. The reasion for the failure was my poor welding. The other weld on the long side had no penetration at all and the other could not take the strain. We simply re welded the engine mount propperly this time. No thicker tubing, no gussets, oozing with confidence that it will hold.

It also turned out one of my shock absorbers had bent so it needed replacing,

We also managed to re install the gearbox, assemble and install the reborn uprights with new springs, change the front pads and install the new Whiteline ARB. Whitch proved to be a bit more laborious than I first thought. But I'snt that the case every single time u go and change something.

The new ARB was an inch narrower than the one I had so it could't just slip above the TCA's like the old one did but needed to be installed below. Whitch is not ideal since the drop links I have require alot of room. The installation isn't all done yet but i gathered the concept will work and only requires some minimal grinding and cutting work.

New set of front springs



Sneak peak of the new arb.


The nose sat somewhat two centimeters higher whith the new springs and strangely enough felt softer than before. It got me thinking have I been bottoming out my front shocks all these years with virtually no inward suspension at all. Remains to be seen when I drop the nose to its usual height.
Would be strange to suffer from excess body roll with solid bottomed out front end. As I said strange. Or maybe the new spings need to be compressed for a while I dont know. Time will tell. Hopefully more tomorrow.

[Roadsport]

Re: Escort Sigma 1600 Race Car

So here's where we are today:

- New engine mounts done. well repaired
- New ARB done
- Service the front strutsdone
- Fix the gear box oil leaks number 2 and 3 done
- New brake pads for the front brakes. done
- Stiffer front springs done

Busy afternoon

[Roadsport]

Re: Escort Sigma 1600 Race Car

OK Front suspension mods all done now. And looks ok to me. It seems firm yet has some flex. For some ODD reason the previous set up was on softer springs but still felt nearly rock hard and even so had body roll issues. Quite eager to find out how this feels.
So as usual I took some pics if someone is interrested in similar mods.


I used the Burtons drop link kit. The drop link bracket had a trianglular hole in it. So to make sure the bracket will not rotate on the sway bar rather than push down on it I made three flat spots to match.


See? Will not slip.



Comparing the old and new



The Whiteline one was narrower. Whicth makes it a bit lighter but as said earlier will not slip above the TCA's











ARB connecting rods were bit of a compromise. In a perfect world they could have been shorter but for now I only had female uball rod ends at hand.

[exboyracer]

Re: Escort Sigma 1600 Race Car

Looks good!

[Roadsport]

Re: Escort Sigma 1600 Race Car

Thanks ex. Had to repair the welds on the other engine mount too. It was distorted too. And as a bonus round I noticed some play in the rear axle. Cant wait to see what has given up there.

[Roadsport]

Re: Escort Sigma 1600 Race Car

Well what do you know. All packed up and ready. Tomorrow I'll sort the tracking and then I can just lay back and enjoy my summer vacation.



The play in the rear axle proved to be bolt and nut related. Wrong bolts in the chassis side uniball joints Holes in the link towers are 10mm but the uniball socket eye was 12mm
I believe this is just another case of too many cooks in the citchen. Tricky to spot afterwards though. Felt all good to hand when tightened as the spacer squees nicely against the link box walls. But when loose there was a world of play in the links. Luckily the bolts did not snap.
A bit of drilling and 12mm bolt took care of that issue but all the play was not gone.
When man handelling the propeller there was still some play. For some odd reasin the pinion bolt sad come loose Tightened it up again and the rear seems as solid as an .... well theres no play anymore.

[Roadsport]

Re: Escort Sigma 1600 Race Car

except in the rear wheel bearing

[andy escos]

Re: Escort Sigma 1600 Race Car

wow what a build you got some patience with all the set backs you have had but it will be worth it in the end .

[Roadsport]

Re: Escort Sigma 1600 Race Car

Thank you. Well to tell the truth I've not been very patient nor composed here in the real garage, I just don't post about it. I've learned the hard way that ignoring or understating any found foult or malfunction will come back to bite you. I literally spent 3 hours on the phone this morning trying to find a Finnish dealer with the Torino GT wheel bearings in shelf. In the end I found one and they should be with me tomorrow. Thank god I'm on summer vacation so I have time to play along with the antics.
You are right about it all beeing worth it. I just love a car with that all solid feel when nothing wobbles or rattles ( or leaks )

[wide ka]

Re: Escort Sigma 1600 Race Car

looking good

[exboyracer]

Re: Escort Sigma 1600 Race Car

Good luck with getting rid of all the wobbles and leaks, I've been trying to do that for nearly four years!