Escort Sigma 1600 Race Car

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  • Roadsport
    Racer
    Decade Plus User
    • Dec 2008
    • 2106

    Re: Escort Sigma 1600 Race Car

    Funny how sometimes bad news are infact great news. I had my injectors tested and the result was a disaster. "Bin them" was the recommendation. They had some 50% differences in total volume between them on partial load near idle and 30% on full duty. I ordered a new set on the spot. All this cost me 400€ but I'm still smiling and feeling light at heart.

    So after work I raced to the garage to start putting the car back together. I installed the new fuel lines which proved to be a good move. The old fuel feed line had leaked in its protective pipe. The stagnant fuel inside the pipe had softened the hose and it made some alarming cracking sound when bent. This new hose is higher quality and stronger and can be submerged to fuel. Some fuel hoses apparently can't.

    The new iinjectors are a 70cc's bigger so I need to get the car on the rollers to get it mapped for the new squits. If it starts to run proper that is.
    Thought I'd stick in the new manifold on while I'm at it to see how it performs. So I needed to spray on the coating 24h before installing.
    The coating was very thin and left the media blasted surface quite grainy. Propably blasted with too coarse media for this coating. Nevertheless It does it job protects against corrosion and even more so acts as a heat insulation. Looks almost like cast plastic when dry.





    So I still have a week to make it to the season finals.So that feels like a real fighting chance. The new injectors should arrive tomorrow or on monday. If the car starts to run properly I was promised it would be mapped by the end of the week.
    "Failure is always an option." - Adam Savage

    Comment

    • madragon199
      Pit Crew
      • May 2010
      • 1139

      Re: Escort Sigma 1600 Race Car

      Great news ..hope you have solved the problem..watching with interest..
      Cheers mark

      Comment

      • dug112y
        Spanner Monkey
        • Dec 2008
        • 298

        Re: Escort Sigma 1600 Race Car

        is it possible the fuel hose has deteriorated and contaminated/blocked injectors/filter/pump or regulator?
        track fiesta on all the right bits.....

        Comment

        • Roadsport
          Racer
          Decade Plus User
          • Dec 2008
          • 2106

          Re: Escort Sigma 1600 Race Car

          My thoughts exactly. Only the injector specialist reckonf there would be some debree in the injectors filters but according to him there was none. But still I can't help but think these things are somehow linked. And on that note I changed the fuel lines to a quality hose. And renewed the filter. I still need to flush the fueltank.
          I think the inferior fuel hose don't take well to these new petrols with 5% ethanol in them.
          "Failure is always an option." - Adam Savage

          Comment

          • Roadsport
            Racer
            Decade Plus User
            • Dec 2008
            • 2106

            Re: Escort Sigma 1600 Race Car

            Manifold and the rest of the system installed for good today. Made an additional bracket for the manifold for added support, installed new fuel lines and re routed the oil lines. Busy day but I'm very happy with the outcome.








            "Failure is always an option." - Adam Savage

            Comment

            • Roadsport
              Racer
              Decade Plus User
              • Dec 2008
              • 2106

              Re: Escort Sigma 1600 Race Car

              Got the official test chart. Maximum flow cc/min was 288cc worst and 342cc "best". Dynamic test showed 27cc's in worst and 39,6cc's in the best.
              The car now seems to hesitate when starting to move and stalls easily. But soon picks it self up and can now take load. Only the new mani seems to leak from the overlap joints and may throw the lambda off so I need to take it out and seal the joints.
              "Failure is always an option." - Adam Savage

              Comment

              • Roadsport
                Racer
                Decade Plus User
                • Dec 2008
                • 2106

                Re: Escort Sigma 1600 Race Car

                Sealed the manifold , dropped the fuel pressure to 3bar and re calibrated the throttle body. Now the car acts nicely. The TPS had trouble noticing the tiniest openings of the butterflys. Hence the hesitation and stalling when calmly lifting of the clutch. After re calibration I feel the car is ready for rollers. The maps are obviously off but now it moves and can deal with load. I'm booked for thursday evening. And hopefully on friday morning I'll be off to the season Finals.
                "Failure is always an option." - Adam Savage

                Comment

                • Matt75
                  Mechanic
                  • Mar 2011
                  • 797

                  Re: Escort Sigma 1600 Race Car

                  Good to hear things are getting sorted. Must be very frustrating.

                  Matt

                  Comment

                  • Roadsport
                    Racer
                    Decade Plus User
                    • Dec 2008
                    • 2106

                    Re: Escort Sigma 1600 Race Car

                    Its now sorted! The rollers show its not missing a single pony. Infact due to the new manifold it's even gained some between 4000 to 6000. Some 10 to 20Nm more to be more precise.

                    "Failure is always an option." - Adam Savage

                    Comment

                    • Graham
                      TURBOSPORT SPONSOR
                      Turbosport Subscriber
                      Turbosport Moderator
                      Turbosport Administrator
                      • Feb 2006
                      • 25214

                      Re: Escort Sigma 1600 Race Car

                      excellent news, well done
                      sigpic
                      https://www.facebook.com/penguinmotorslimited?ref=hl

                      Comment

                      • Group4_Mark2
                        Pit Crew
                        Decade Plus User
                        • Dec 2004
                        • 1782

                        Re: Escort Sigma 1600 Race Car

                        Great job getting it sorted. Hopefully you will have many good races with no more problems
                        To finish first, you must first finish

                        Comment

                        • Roadsport
                          Racer
                          Decade Plus User
                          • Dec 2008
                          • 2106

                          Re: Escort Sigma 1600 Race Car

                          Yeah, if the dry sump belts could just stop snapping. That would be great.
                          "Failure is always an option." - Adam Savage

                          Comment

                          • RWD fords rule
                            Racer
                            Decade Plus User
                            • Feb 2006
                            • 3579

                            Re: Escort Sigma 1600 Race Car

                            Have you space to fit a wider set of pulleys and a decent strong dry sump drive belt, honestly I think that the usual dry sump belts are just waiting to fail, they are the flimsiest things I have ever seen & they keep the engine together, the only thing I would trust those little belts to drive is a sowing machine lol!

                            Good work with the manifold, I was expecting more mid range with the relatively small pipe diameters and long primary lengths you chose, great that the top end is the same as before, very best of luck with it
                            "Horsepower sells cars, torque wins races" - Enzo Ferrari

                            Comment

                            • Roadsport
                              Racer
                              Decade Plus User
                              • Dec 2008
                              • 2106

                              Re: Escort Sigma 1600 Race Car

                              There's your problem.



                              Which resulted in this.



                              And in turn to this. Some colors in the oil




                              NOTE TO SELF: Do not reuse the locking pin on the main axle.
                              Last edited by Roadsport; 16-09-2013, 11:30.
                              "Failure is always an option." - Adam Savage

                              Comment

                              • Group4_Mark2
                                Pit Crew
                                Decade Plus User
                                • Dec 2004
                                • 1782

                                Re: Escort Sigma 1600 Race Car

                                That is a seriously messed up looking belt and locking pin.
                                To finish first, you must first finish

                                Comment

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