Mk1 escort van rolling/running project

[freddy6868]

Well this is how the van stood back in july i bought it thinking it was finished and complete but i would say 90% of the work had been done and some of it is quite cowboyish as you will see but easily fixable it also had all the right pieces although it had been put together with a rough hand.

http://i296.photobucket.com/albums/mm177/freddy686868/van.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/van2.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/van3.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/van4.jpg
So today (13/072010) i went to pick it up. Shortly after sorting out the paperwork and money side of things i started the van up from cold with out the choke and drove off. I was just joining the A13 thinking god this van runs very well considering it has been standing a year since it's rebuild. Then all of a sudden the van looses power and comes to a stop. Totaly gutted isn't the word! So i get out make sure the choke isn't stuck open and all the leads to the dizzy were secure and tried to start it again. Oddly enough it started, so off i go again with my brother in his 106 following only for the same thing to happen again! Then for a third time. By now i was getting pritty ****ed off with my newly aquired pride and joy UNTILL i remembered what the seller told me. The last thing he told me was the petrol is seriously low but you should have enough to make it to the petrol station 10miles away so i sent my bro to buy a jerry can and petrol which he returned with very quickly. So i put the petrol in and started the engine thinking this is going well so for the forth time in half an hour we set about continuing on our 200+mile trip home. I was really nervous about the van stopping again as i thought the carb wasn't set up correctly and was causing it to cut out when hot.
I can't explain how relieved and how happy i was when the van made it to the petrol station for more juice and wind in the tyres. From there on it drove brilliantly apart from the wheels needing balancing and the tracking. It trundled along the motorway with out any weird noises being made at around 80mph returning around 35mpg whih isn't bad for a 40year old car.
So after looking at the van more and spending over 4 hours in it i found that there are some simple jobs to be done to finish it off lovely. The only update i have apart from the journey is a picture of it outside my house. It will be off for M.O.T tomorrow as i got home too late today to carry out a full one. So fingers crossed.
I thought it would be hard to enjoy a slower and even more basic car than the rallye but i was totaly wrong apart from the 4 speed box it is very comfy and fun to drive and i look forward to driving it a hell of a lot more! They also say the first long distance trip is the bigest test for any old car.
http://i296.photobucket.com/albums/mm177/freddy686868/13-07-10-19-52.jpg

15/07/2010
Well i had the van up on a mates ramps to have a real poke around the underneath to check for nasties in the form of rust which i'm happy to report is very minimal it might need a passanger floor pan in around 2years which is expected of a car of this age and there are two patches needed at in the rear wheel archs just to stop the rust advancing any futher. Whilst i was there i had to put spreader plates on the SEAT bolts! They were just bolted stright in to the floor with a couple of washers. Vairious bolts do need shortening through out the van as you can see from the picture of the back.
Just a couple of pics of it on the ramps
http://i296.photobucket.com/albums/mm177/freddy686868/15-07-10-18-41.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/15-07-10-18-41001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/15-07-10-18-41002.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/15-07-10-18-41004.jpg
Putting the van to good use again for the second day by taking my toolbox into work (it's about time though as it's been in my house since christmas :P) and the van hasn't been on the road since 1981.
http://i296.photobucket.com/albums/mm177/freddy686868/15-07-10-20-02.jpg

15/07/2010
I've also got a brand new NOS ford clock off my cousin whos father found it in the garage about a week ago and was due to throw it out! Result, what are the chances
http://i296.photobucket.com/albums/mm177/freddy686868/15-07-10-21-25001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/15-07-10-21-25.jpg

17/07/2010
Well already the wagon is playing up after covering only 400miles i believe the coil is packing up as when i rev the engine anything over 3.5k ish it starts to miss and when the engine has been run for a while so a new coil is on the way.

[freddy6868]

22/07/2010
Good news the van is up and running again! The problems were the ignition timing was miles and miles out, the carb wasn't set up properly and there was only around 8l of petrol in the tank. Going well now! I've also been told by my old mans mate who set it all up that the engine has i nice little cam in it too :)

10/08/2010
wrong again the problem is back but i have just emptied loads and loads of crap and rust out of the petrol tank so it's going to get a good pressure washing out and put back on when dry.

11/08/2010
Result! The van will run off a 5l can of petrolium wedged between the seats with the fuel line dipped in it but it won't run out of the proper petrol tank so once i have cleaned the tank out and put it back on the job will be a good un although i am thinking about having a nice ally replacement made next time i have problems with it. So it will be up and running well again soon!

16/08/2010
Some bits to keep the van going and some to change the feel of it as the old steering wheel is shocking
The new petrol tank i spent ages looking for on the net
http://i296.photobucket.com/albums/mm177/freddy686868/vantank.jpg
The rs2000, mexico style steering wheel that is so badly needed
http://i296.photobucket.com/albums/mm177/freddy686868/sterringwheel.jpg
And finaly a good condition second hand fuel sender unit complete with float and filter.
http://i296.photobucket.com/albums/mm177/freddy686868/senderunit.jpg

[freddy6868]

11/10/2010
Well since having the engine set up the problem with it cutting out started again so i decided to take the plunge and remover the old fuel tank which was rotten and blocking the filter in the tank thus starving the engine of fuel.
So out with the old
http://i296.photobucket.com/albums/mm177/freddy686868/31-07-10-19-04.jpg
In with the new. Luckily i found a nos tank that someone had bought for thier kit car and never used so i had painted it up and slung it under there. It wasn't the repoduction one after it was one off ebay for £53!Bargin!
http://i296.photobucket.com/albums/mm177/freddy686868/14-09-10-17-01.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/14-09-10-17-01001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/30-09-10-14-07001.jpg

The next thing i done was (with lots of help from my mate kiwi) was get all the clocks working. So after a few hours of potching we found the problem which was a broken power wire coming from the fuse box.
AFTER that i changed the wheel bearing on the drivers side and loved it as it just fell apart nicely although i had to use my mates hydraulic press.
Well since having the engine set up the problem with it cutting out started again so i decided to take the plunge and remover the old fuel tank which was rotten and blocking the filter in the tank thus starving the engine of fuel.
http://i296.photobucket.com/albums/mm177/freddy686868/30-09-10-14-07.jpg
When i changed the wheel bearing no oil came out of the axle so i thought it would be a good idea to top up the oil and found out that who ever put the bolt in the axle wreaked the thread and the axle was leaking oil so off to the hardware store that sells all types of weird and wonderful sized stuff and 80p later i had myself a new 1/2 unf bolt and copper washer
http://i296.photobucket.com/albums/mm177/freddy686868/30-09-10-17-31.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/30-09-10-17-31001.jpg
So the list of to do's was now getting shorter just leaving the below
Just the windscreen rubber and a new exhaust and the van would be up to my standards for now. . . . . . . BUT whilst i was under the van trying to stop the exhaust banging off the chassis i noticed one of the dampers were leaking and all the bushes had perished which got my thinking i should really just change them for peice of mind.
So first to be done was the windscreen and after taking four hours to put it in wrong myself i gave my mate who works for a well know automotive window fitting firm and he fitted it with abit of a potch but having all the gear made it much easier!
http://i296.photobucket.com/albums/mm177/freddy686868/04-10-10-16-52.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/04-10-10-16-52003.jpg[/QUOTE]
Then i moved onto removing the leaf springs to fit the poly bushes inplace of the knackerd ones and i also have a nice set of adjustable avo dampers to go on there from from Peter Lloyd Racing which are nicely priced.

As you can see i couldn't just change the bushes i had to got the whole hog and strip everything down and paint it up properly so it has taken abit more time effor and money that i'd thought.
http://i296.photobucket.com/albums/mm177/freddy686868/11-10-10-16-58.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/11-10-10-17-52001.jpg
Next months project is to have a custom made stainless exhaust system fitted by prospeed which i'm looking forward to as the van will be near enough sorted!

13/10/2010
Not much to show but a fair bit to tell. When i was dismanteling the leaf springs the bolts holding them together sheered which i supose is because they are made out of monkey metal and have been under tension all thier life. So in my dinner breaks over the last three days i knocked these up out of stainless steel as i couldn't find the bolts anywhere.
http://i296.photobucket.com/albums/mm177/freddy686868/13-10-10-15-11.jpg
I have also made a battery tray out of some sheel metal with uprights that bolt through the floor and a bar over the top of the battery located behind the passanger seat. More pictures of it fitted when it is light.
http://i296.photobucket.com/albums/mm177/freddy686868/14-09-10-17-02-1.jpg
The final picture of the day for me is of my new dampers. Which are all fitted up with the poly bushes and it has transformed the way the van drives and handles.
http://i296.photobucket.com/albums/mm177/freddy686868/13-10-10-15-12001.jpg
I have also mounted a fire extinguisher on the wheel arch in the back as i was given it out of a mates old rallye car so that is looking good although i hope it never has to be used.
The van is on the raod and driving better than ever going to go out for a spin in it tonight because i have missed driving it over the last week. Gutted i didn't take more pictures of the build up but i was in a rush to beat the darkness so had no time to take photos (yet).

15/10/2010
I found a rear door seal!!!! But i think it is boarder line useable but i have one none these less.
Also found some other goodies for the van, some not even needed
http://i296.photobucket.com/albums/mm177/freddy686868/15-10-10-18-36001.jpg
These also finish the back off nicely just need to fit the bumpers now after they have had some work done, although i have bought some off ebay too :(.
http://i296.photobucket.com/albums/mm177/freddy686868/15-10-10-18-15.jpg
before
http://i296.photobucket.com/albums/mm177/freddy686868/15-10-10-18-22.jpg
after
http://i296.photobucket.com/albums/mm177/freddy686868/15-10-10-18-26.jpg
The left side shows the light with out the covers on and the right with the cover on
http://i296.photobucket.com/albums/mm177/freddy686868/15-10-10-18-44001.jpg

[freddy6868]

20/10/2010
There is still some more progress although i have slowed down on the buying of things now as i am spent out this month i have turned to mates for favours on the items i have bought so far this month.

I bought some mk1 escort van quater bumpers off ebay for a pricey sum although they did come with brackets and bolts but i knew i could get them stripped back and painted up nice on mates rates (which is mainly beer :D)

http://i296.photobucket.com/albums/mm177/freddy686868/quaterbumpers.jpg

More pictures of them soon as they have been stripped back to metal and are being etch primed and painted gloss black very soon.

After i have bought the quater bumpers off the net i actually found some bumpers off the back of a mk2 van so i sent them off to a mate in the local body shop to see if he could blast all the rust out of them patch the holes/blend in the new metal into the old metal then finally paint them. One is mint the other has suffered from years of being in the ground so fingers crossed. Here is a poor photo of the worst one and there will also be more updates on that soon hopefully.

The red ring is showing where the rot has eaten into the bumper badly.
http://i296.photobucket.com/albums/mm177/freddy686868/15-10-10-18-36002.jpg
Like i say this is nothing exciting but it is cheap and cheerful progress. Next month i will be changing the

engine mounts/gearbox mounts (IF I CAN EVER FIND NEW ONES FOR SALE)
a custom made exhaust made by Prospeed in cardiff in place of the crap on there now
Make another new pin for the other leaf spring shackle as the bolt has sheered off
and sort the handbrake as it isn't holding very well due to the rubber attched to the handbrake cable and brake bar. I'm guessing that it is only holding on the drivers side.
HHHMMMMMMMMM
These carbs are tempting me to fit them on the crossflow too! Left over from my last project car are some gsxr750 srad carbs that would suit it down to the ground.
http://i296.photobucket.com/albums/mm177/freddy686868/20-09-10-16-20001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/20-09-10-16-20.jpg

24/10/2010
Well the bumpers i bought off ebay have been painted and are on the van all fitted up with stainless bolts. I'm very happy with them although one has abit of a ripple in it, but it is 30years old.
before
http://i296.photobucket.com/albums/mm177/freddy686868/22-10-10-16-19002.jpg
after
http://i296.photobucket.com/albums/mm177/freddy686868/22-10-10-16-37002.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/22-10-10-16-38.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/22-10-10-16-37.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/22-10-10-16-37001.jpg
I also had a bash at repairing the other bumpers the other day and they are all ready to be welded up which i'm going to do myself.

All cleaned up and stripped back to see the extent of the rust damage
http://i296.photobucket.com/albums/mm177/freddy686868/21-10-10-15-13001.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/21-10-10-15-13.jpg

All the thin metal cut out and new patches made.

http://i296.photobucket.com/albums/mm177/freddy686868/21-10-10-15-48001.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/21-10-10-17-13001.jpg
Old pieces of the bumper with the new pieces above and number three had to be bent into the correct shape which took a fair amount of time.
http://i296.photobucket.com/albums/mm177/freddy686868/21-10-10-17-13.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/21-10-10-17-14001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/21-10-10-17-14.jpg
My new dash surround compaired to the old one
http://i296.photobucket.com/albums/mm177/freddy686868/23-10-10-14-28001.jpg
Painted a nice satin black
http://i296.photobucket.com/albums/mm177/freddy686868/23-10-10-14-51.jpg

30/10/2010
Out with the falling off floor touching rubbish and in with the well made custom 2" pro speed exhaust i had fitted today.
http://i296.photobucket.com/albums/mm177/freddy686868/22-10-10-16-37.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/15-07-10-18-41001.jpg
In this pic you can see even with the escort up on the ramps and the axle on full droop the exhaust is very close to the axle.
http://i296.photobucket.com/albums/mm177/freddy686868/15-07-10-18-41002.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/15-07-10-18-41004.jpg
In the end i went for a two box system to keep the noise levels down on the motorway and these guys done a great job and i would recomend prospeed to anyone. It did take a fair while but you can't rush quality. I know the prictures are poor but hopefully everyone willget the idea.
Had the middle box mounted just before the axle as you can get it higher up under the car
http://i296.photobucket.com/albums/mm177/freddy686868/30-10-10-17-10001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/30-10-10-17-09.jpg
The nice 2 1/4" tail pipe that is just right and not too chavy.
http://i296.photobucket.com/albums/mm177/freddy686868/30-10-10-14-01.jpg
An extra mount was also fixed to the underside to stop exhaust moment that caused the old one to knock off the fuel tank and chassis.
http://i296.photobucket.com/albums/mm177/freddy686868/30-10-10-13-57.jpg
The new poly bush kit and avo dampers too.
http://i296.photobucket.com/albums/mm177/freddy686868/30-10-10-14-01001.jpg
New engine mounts and gearbox mount ready to go one when i have time then she really will drive just like a brand new car.
http://i296.photobucket.com/albums/mm177/freddy686868/30-10-10-17-46.jpg
I also bought these from rally design as the rubber bobbings i bought don't suit the lesser 1300 engine mounts fitted to the van
http://i296.photobucket.com/albums/mm177/freddy686868/RD407.jpg

[freddy6868]

04/11/2010
I fixed the perished rubber on the hand brake but i have only just learnt how to adjust the handbrake up properly and you have to do it manually!!!!!haha
http://i296.photobucket.com/albums/mm177/freddy686868/25-10-10-17-00001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/25-10-10-17-00002.jpg
Just a small update seams the rear light screws were rusting i decided to replace them with stainless steel ones but as is the case with this van the guy who built it wasn't into finishing touches and had put the lights in with wood screws!!!!!!!
Out with the old and in with the new spacers that i knocked up in my dinner times in work again :)
http://i296.photobucket.com/albums/mm177/freddy686868/04-11-10-18-56.jpg
Cleaned out the lights
http://i296.photobucket.com/albums/mm177/freddy686868/04-11-10-18-20.jpg
All nicely bolted together and they are now fitted in the van. I had a look along the rear quaters when the lights were out and the good thing is they are very straight and theres no filler in them WOOP!
http://i296.photobucket.com/albums/mm177/freddy686868/04-11-10-18-22002.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/04-11-10-18-22001.jpg

11/11/2010
Well went down cardiff bay to have a nose around the wrc cars in the load lugger and on the way home on a round about the clutch cable snapped so i had to limp home slipping it into gears using the rev and push method :/ but it's home and the part is inexpensive so i wil sort it soon.

14/11/2010
Well i ripped the brake and clutch pedal out of the pedal box as they both sit on the same pivot mainly to find out what happened to the clutch and to replace the pedal bushes that yet again hadn't been fitted! The good news is though the clutch cable hadn't snapped a small pin had came out disconnecting it.
Pedals missing thier top hat bushes and as you can see the clutch pedal hole has worn oval so i will have to offset bore that out and use an oversize top hat bush to replace it.
http://i296.photobucket.com/albums/mm177/freddy686868/12-11-10-17-40.jpg
troublesome pin
http://i296.photobucket.com/albums/mm177/freddy686868/12-11-10-17-40003.jpg
worn pivot pin
http://i296.photobucket.com/albums/mm177/freddy686868/12-11-10-17-40001.jpg

15/11/2010
Well some good progress has been made on the pedals and thier bushes.
A new pivot pin had to be made as the old one was worn and no good. The undercut has been cut into the bar but it needs a flat in one end now to locate in the pedal box
http://i296.photobucket.com/albums/mm177/freddy686868/15-11-10-18-46.jpg
Below shows the clutch pedal with the offset hole bored out to 7/8" 3mm more than the standard hole! You can see the difference in hole size is clear from the picture. Ignore the silver mark on the pedal that is where a washer took the paint off the pedal in the old holes position.
http://i296.photobucket.com/albums/mm177/freddy686868/15-11-10-16-34.jpg
Last but not least the two top hat bushes that have been made so far. There is a third to be made that will locate inbetween the clutch and brake pedal but i had to work out how long the shoulder has to be to seperate the pedals so that will be made sometime this week. As you can see again the difference is clear between thier sizes (standard on the right oversize on the left).
http://i296.photobucket.com/albums/mm177/freddy686868/15-11-10-18-47001.jpg
When i get time i will also strip the pedals back and paint them up so they are like new again.

20/11/2010
Flat machined in the pivot bar and the bar has been hardened also the middle pedal bush all knocked up ready for when i can be bother to strip back the pedals and paint them up.
http://i296.photobucket.com/albums/mm177/freddy686868/20-11-10-20-38.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/20-11-10-20-39.jpg

21/11/2010
handbrake adjusted up, FINALLY!
Exhaust manifold off, the stud has been drilled out and was in the process of being shelled out the remainder of the stud with a carbide burr so it could be tapped out. That will have to be finished tomorrow then and hopefully the pedals can be installed and then it is off for the small amount of welding it needs done and them a good dose of wax oil ready for the winter. Also before the exhaust manifold goes back on i will re-wrap the manifold properly using the heat wrap my mate Curl donated to the escort fund.

23/11/2010
Well after looking at this design i spotted a big flaw in my design.
http://i296.photobucket.com/albums/mm177/freddy686868/20-11-10-20-39.jpg
As the bushes are a press fit into the pedals every time i push the
one pedal it will move the other too! Oviously i didn't want that so another bush has now been made and they have all been pressed in.
Nice new painted pedals and bushes inserted
http://i296.photobucket.com/albums/mm177/freddy686868/22-11-10-16-53003.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/22-11-10-16-53.jpg
I had trouble fitting the pedals so i pulled the pedal box out and thought it needed a paint too as it looked rough as hell, so that will be stripped down and painted soon. The accelerator pedal was also covered in some sort of paint so i stripped that back to find it was silver so it will be left like that.
I also finished removing the broken stud from the head by drilling out the stud using as 5mm drill then a 6mm carbide burr untill it broke through to the threads in the head. After that it was a simple case of tapping the remaining stud out. Before i put the mainfold back on it will also be heat wrapped using stainless steel wire the hold the wrap on not the crappy jubilee clips used now.

[freddy6868]

29/11/2010
More work carried out on the escort tonight, i came straight in from work and started wrapping the manifold. I didn't have enough to wrap the manifold from the head so i wrapped it from where the 4 go into two and tidied up the old wrap the best i could.
This is how it started
http://i296.photobucket.com/albums/mm177/freddy686868/29-11-10-16-16001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/29-11-10-16-16.jpg
This is how it looked over two hours later!
http://i296.photobucket.com/albums/mm177/freddy686868/29-11-10-18-15001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/29-11-10-18-14001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/29-11-10-18-14002.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/29-11-10-18-15.jpg
I also bought these aswell because the ones on there now are rubbish although the copper nuts are going in the bin in favour of some high quality stainless nuts.
The picture isn't great but i stole it off the website i bought them off.
http://i296.photobucket.com/albums/mm177/freddy686868/xexhaustl.gif
I just have to sort out the pedal box housing put them back in and then put the manifold back in with the new stud kit and it's away we go again!

[freddy6868]

I now have everything all painted up nice and ready to go onto the escort but i have got a serious case of man flu and i'm not going anywhere in the snow so it's going on hold now, hopefully no more than a week.

http://i296.photobucket.com/albums/mm177/freddy686868/02-12-10-11-49.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/02-12-10-11-50.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/02-12-10-11-50001.jpg

[Andyc]

getting there Jon looking as good as ever

[bluevan1]

looking good there m8.
had one of these mk1 escort vans this year but had to sell wished a kept it.....:(
all the best with ur project........

[rsjon]

nice motor,do you use it everyday?

[ASHLEY]

Cracking job :)

[oldskooler]

excellent work there. looks the bizz.

[tibbs]

Cracking job there, looks great :cool:

[pushrod]

Looking fab.
Any pics? :)

[vinny]

nice work m8

[freddy6868]

Engine mounts fitted (more poor pictures to show that)
http://i296.photobucket.com/albums/mm177/freddy686868/06-12-10-15-53001.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/06-12-10-15-53002.jpg
I then went on to fit the new stud kit and the exhaust manifold so that is all fitted and out the way
I had to remove the master cylinder to get to the drivers side engine mount and in the process i broke the steel brake line, so a mate knocked me up a nice copper on to replace it.
All i have to do is fit the pedals/pedal box the master cylinder and the brake line, bleed the system and away we go again!

[freddy6868]

nice motor,do you use it everyday?

Nah i have an almost brand new car to travel the 60miles a da back and forth work although i do use it when i can to go anywhere.

[freddy6868]

Also just want to say a big thanks for all the kind comments!

[freddy6868]

Next on the shopping list is a set of N.O.S genuine Ford rear door seals which are on a silly £167 on ebay atm but we shall see what they go for and who buys them ;)

[76mex]

nice work there yes your right about silly prices regarding the bits but these vans are getting pretty thin on the ground now its nice to see another one on the scene:)

[freddy6868]

nice work there yes your right about silly prices regarding the bits but these vans are getting pretty thin on the ground now its nice to see another one on the scene:)

They they went for 285 in the end!

[freddy6868]

nice work there yes your right about silly prices regarding the bits but these vans are getting pretty thin on the ground now its nice to see another one on the scene:)

Yeah i wanted a 2door but i seen the van on the net went to look at and bought it after selling my little 106 rallye. I love it to pieces as it is something different.

[freddy6868]

Still out in all weathers as there is a 106 in pieces in the garage where the escort is ment to be sitting high and dry. Silly french cars!

http://i296.photobucket.com/albums/mm177/freddy686868/20-12-10-11-37002.jpg

Mexico arches holding plenty of snow
http://i296.photobucket.com/albums/mm177/freddy686868/20-12-10-11-37003.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/20-12-10-11-38003.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/20-12-10-11-38005.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/20-12-10-11-38008.jpg

[freddy6868]

It now looks like this only hours later and it's still snowing.

http://i296.photobucket.com/albums/mm177/freddy686868/20-12-10-14-33001.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/20-12-10-14-33006.jpg

Hello again Monkey

http://i296.photobucket.com/albums/mm177/freddy686868/20-12-10-14-33007.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/20-12-10-14-33012.jpg

Looks like it has a small bubble arch now.

http://i296.photobucket.com/albums/mm177/freddy686868/20-12-10-14-33.jpg

[freddy6868]

Well on the 2nd of January i took part in an auto test in a quary and had great fun learning how to drive a rwd car/van (same chassis as the car). Although i came last as i didn't want to damage it i had fun and learn abit and i now know i need to reduce the understeer although i was running road tyres that didn't help. When the photos load up onto photo bucket i will put them up to show you. Don't linch me though as the van is stinking!
http://i296.photobucket.com/albums/mm177/freddy686868/90right.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/wilsonscar.jpg
The start of a nice little slide there
http://i296.photobucket.com/albums/mm177/freddy686868/drifting1.jpg
Really happy with this picture :)
http://i296.photobucket.com/albums/mm177/freddy686868/drifting2.jpg
time control
http://i296.photobucket.com/albums/mm177/freddy686868/timecontrol.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/hairpin.jpg
LUKE'S CORNER had to take it meag easy through there them skips could do some damage
http://i296.photobucket.com/albums/mm177/freddy686868/slippycorner-1.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/straight.jpg

[Mark M]

looks good getting used. well done. . . :cool:

[freddy6868]

looks good getting used. well done. . . :cool:

Thanks, alot of people at the autotest told me i was mad taking it out. But i was sensible and went for a slide where there was room.

[freddy6868]

A couple more pictures from the autotest the first one was a quick slide flat out in second. :p
http://i296.photobucket.com/albums/mm177/freddy686868/Autotest_020111_186_copy.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/Edit2_2.jpg

[Mogsmex]

Good stuff, nice to see 'em being used properly :cool:

[bluevan1]

nice van .
but a wouldnt be doing that .but eveyone to there own.:cool:

[mike77cos]

Like that a lot

[freddy6868]

Thanks i was after a two door but seen this and fell in love with it. So progress being made on her soon too.

Well as you can see from the title the four speed box is frying my head on the motorway but is great for round town. but what pushed me over the edge was the 27mpg so i had a look under the van and i could see that all the mod work needed to fit a 5 speed had been done. i.e move the gearstick hole and gearbox mount back. All i have to to is buy a different clutch which is great as mine is on its last legs mod the propshaft and buy a quickshift and drop it all in.

Im picking up the 5 shifter tomorrow and the propshaft at a bargin price and at the end of the month i will be concentrating on reducing/eliminating the understeer by fitting the rollor top mounts i bought along with a twin cam anti rollbar which will give me more castornabout a deg or two and some adjustable tca's to add some nice camber and last but not least a double width kit to reduce the body roll up front. Pictures will follow when im on the pc.

I have been doing some working outs too and i have noticed the 1st,2nd and 3rd gear on the 2.8i capri gearbox i m using will be longer than my current box making the escort a little slower. 4th gear is the same ratio as the one in the four speed so anything in fith is a bonus Soooo i am going to reduce the tyre diameter by 1.5-2" and that will make the first three gears shorter than the original gears and then ive still got about 25 mph top end which means it will have the same finalmdrive speeds as and s2 106rallye box.

[freddy6868]

Well after a full 7 days of chasing a gearbox that has been sitting in the back or a scrap yard all that time in a mk5 cortina estate with a 2l pinto in. So here it is! A quick question is should there be play in the input shaft as there is a little, i am just hoping that the bearing in the flywheel supports it.
capri 2.8 type 9 box
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0327.jpg
The end of the prop and the rubber donut that it bolts too
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0326.jpg
Wreaked i know but another problem is that the donut is attached to the output shaft and i would like to get rid of it. How would i get rid of this? I'm thinking about turning it off and making a new flange and welding it to the output shaft would that be a good idea?
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0325.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0324.jpg
Here is a picture of the gashness of some people. From what i can see it is a 5 speed type 9 mount bolted throught the floor and a four speed mount welded to it. Which makes me think it has deffo had a 5 speed in it at some point
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0306.jpg
Finally some not very clear pictures of the strengthening brace that hass been removed already to fit a type 9
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0304.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0301.jpg

[freddy6868]

Another photo but this time it is suspension related. My new/old roller top stut mounts that i bought off a mate . Also on the way is a brand new twink arb for the much needed caster and a double width kit to bolt it on both from rally design.
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0330.jpg

[freddy6868]

And some more goodies that arrived today i was going to fit them over the weekend but i haven't recieved the adjustable tca's and the mrs gearbox on her 106 needs upgrading to a 5 speed s1 rallye box.
Double width kit
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0337.jpg
Twin cam antiroll bar
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0340.jpg

[freddy6868]

More shiny bits and now i have a deadline of the 13th to fit all the gear get it set up and sort the starter as i have anOther autotest to skid around in tk see if the bits and pieces have sorted the understeer. Hopefully they will have as the polybushes are going to tighten the front end loads on thier own never mind the changes to the suspention geometry.

The tca's i bought at a bargin price.

http://i296.photobucket.com/albums/mm177/freddy686868/b146b1ea.jpg[/QUOTE]

[freddy6868]

Progress!

Old shite removed. There was no resistance in the arb bushes at ALL. They are mullered. But the tca's are nearly new.

So i had a couple of hours today fitting my nice new shiney bits, or should i say removing the old rubbish. Well the first thing i done was get it on axle stands unbolt the arb brackets in the front corners of the engine bay and the end of the arb that goes through the tca. But i couldnt take the arb out of the brackets so i dropped the tca's off the crossmember all at the sametime.
Up she goes
http://i296.photobucket.com/albums/mm177/freddy686868/a5ed4bf9.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/a59763d2.jpg

Off with the old stuff an the new stuff to go back on

http://i296.photobucket.com/albums/mm177/freddy686868/56fa3760.jpg
Judging by the state on the old arb bushes the double width kit coupled with the hardness of the bushes used i cant see there being much body roll at all!

My new insitu adjustable rosejointed tca's compared to the old ones which were in fairness almost brand new

http://i296.photobucket.com/albums/mm177/freddy686868/1eb3f961.jpg

Old arb brackets gone

http://i296.photobucket.com/albums/mm177/freddy686868/3b675f8f.jpg

New ones fitted :D

http://i296.photobucket.com/albums/mm177/freddy686868/d0f37abe.jpg

Ignore all the rust looking stuff too that is mud that i still haven't washed from underneath

[freddy6868]

Well fridays progress after work was bolting on the tca's and the arb loosely in the high winds and really heavy rain. As i wanted to take the escort to watch a road rally on saturday.

So fridays progress

http://i296.photobucket.com/albums/mm177/freddy686868/d631ac58.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/bc38a11d.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/605fa98e.jpg
So slightly hung over on saturday morning i was back out there on the damp floor but no rain thank god. So i then finished tightening everything up and very roughly setting up the camber and tracking.

http://i296.photobucket.com/albums/mm177/freddy686868/57a45c93.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/c4f1daf4.jpg

All back on the floor and the wheel
Is sitting properly in the wheel arch too!

http://i296.photobucket.com/albums/mm177/freddy686868/882c5713.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/fa1cac7d.jpg

The old position of the wheel

http://i296.photobucket.com/albums/mm177/freddy686868/IMG_0285.jpg

The position of the wheel now.

http://i296.photobucket.com/albums/mm177/freddy686868/4584daf8.jpg

So i took it for a drive saturday afternoon and it turns in very sharp but because it isnt set up it is unstable when it is going over bumps and at higher speeds. So i dropped over a mates to get the tracking and camber set up before we went to watch the rally. I wanted the camber set to 1.5 degs but the safest camber we could set it too was 0.75degs because the steering arms were too short. So if anyone knows for some longer steering arms so i can set up the camber properly that would be brilliant if you could let me know.

[Mark M]

well done. brings back memories lying outside in the rain working on old escorts.:cool:

and the prop with the rubbers. throw it in the bin, and use the 4 speed one. it will fit ok.
and if its a 2.8 box, will need a bit trimmed off the input shaft, and a little play is ok. good luck. ;)

[Mark M]

just re-read. if box has already been on a pinto, it must have already had the shaft shortened. :o
cheers.

[freddy6868]

Yeah it has been shortened already and i was under the impression that the output shaft on a 4 speed is different to a 5 speed?

[freddy6868]

Well i done an autotest on sunday. Had a good little skid but i am in real need of a plated diff to stop the inside wheel spinning up all the power. But the escort had survived another autotest or so i thought, on the way home i went round a round about abit enthusiastically and this haPpened when the back end stepped out on the greasy road.

http://i296.photobucket.com/albums/mm177/freddy686868/93489a6b.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/4b1ed171.jpg

So she is now at a mates paint shop and he is going to do the repair as he is shit hot whennit comes to paint work.
I am also tinkering with the idea of ripping off all the rs stripes and putting mexico stripes on in matt black. It makes sence to me as it is running mexico running gear after all.

And i will be running some 13x6 alleycats im going to buy at the end of the month.

[freddy6868]

Well i recently bumped the van as you all know but. I have found out that the rear arches and sills are welded over the older ones so im having them ripped off and the rear quaters sprayed too. But on to some bigger news.


I seen this in a magazine

http://i296.photobucket.com/albums/mm177/freddy686868/786d954e.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/49f65406.jpg

Shortly after i seen this in a scrap yard

http://i296.photobucket.com/albums/mm177/freddy686868/086ca41b.jpg

Weirdly after that i lost 175 bucks? Hhhmmmm wonder where the hell that went.

[freddy6868]

Abit of progress today
I picked the engine up from the yard and drove home the mile with the engine hanging out the back of the car like this
http://i296.photobucket.com/albums/mm177/freddy686868/bfa6666c.jpg
The whole lot was dumped in there by a fork lift truck but ehen i got home i reliesed that this was a serious lump with some serious weight. . . . So i had to strip it down in the back of the car to unload it.

Finally in the shed

http://i296.photobucket.com/albums/mm177/freddy686868/0e3882f7.jpg
So i took the cam cover off to check for any signs of oil starvation of the top end and i was told it was a really quick engine by a mate and that it was ment to be cammed. So i had a nose and as all these really quick standard engines turn out to be its not but its in geat nick inside so im happy.
http://i296.photobucket.com/albums/mm177/freddy686868/03eaadc7.jpg
mmmm timing chain
http://i296.photobucket.com/albums/mm177/freddy686868/c5164532.jpg

Also if anyone has any info on this conversion i would be greatful for any info i could get hold of to make life easier. Thanks for looking, John

[freddy6868]

Well the flywheel is in being lightened so it started like this.

http://i296.photobucket.com/albums/mm177/freddy686868/0a08d75b.jpg

If you look carefully you can see where i have marked for the material to be removed from the flywheel and that will be about a quater of an inch deep.

http://i296.photobucket.com/albums/mm177/freddy686868/bef9dd9c.jpg
More Pictures of that after the flywheel has had the material removed from it.

Same here, this is crank pulley that drives the alternator, power steering pump and the water pump. I think in needs to go on a diet as it really heavy.

http://i296.photobucket.com/albums/mm177/freddy686868/864d3926.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/01b7a208.jpg

The same as everything else i have taken off the engine the powersteering pump and bracket was really really heavy so that was scraped and i will have to make a new alternater bracket as it mounted on the powersteering pump

[freddy6868]

Well the flywheel is in being lightened so it started like this.

http://i296.photobucket.com/albums/mm177/freddy686868/0a08d75b.jpg

If you look carefully you can see where i have marked for the material to be removed from the flywheel and that will be about a quater of an inch deep.

http://i296.photobucket.com/albums/mm177/freddy686868/bef9dd9c.jpg
More Pictures of that after the flywheel has had the material removed from it.

Same here, this is crank pulley that drives the alternator, power steering pump and the water pump. I think in needs to go on a diet as it really heavy.

http://i296.photobucket.com/albums/mm177/freddy686868/864d3926.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/01b7a208.jpg

The same as everything else i have taken off the engine the powersteering pump and bracket was really really heavy so that was scraped and i will have to make a new alternater bracket as it mounted on the powersteering pump

Not a huge amount done but 20mins in my dinner time and abit of turning produced this. Which i think is a major improvement over standard.

http://i296.photobucket.com/albums/mm177/freddy686868/384d6880.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/39e4c744.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/5eff6c25.jpg

Just got to paint it and mill the timing mark back on the face now.

Bye bye unwanted inertia.

[SHIFTY]

some big updates here mate, fair play :cool:

I do love a mk1 van! :D

[freddy6868]

some big updates here mate, fair play :cool:

I do love a mk1 van! :D

No big changes yet the changes will be really happening at the end of the month when the engine starts to go in

[freddy6868]

Well at the end of the month i will own these pair of bad boys

http://i296.photobucket.com/albums/mm177/freddy686868/f1feaf24.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/631c0c3f.jpg

And a stand alone ecu and wiring loom for the ignition only side if things

http://i296.photobucket.com/albums/mm177/freddy686868/2378f5c0.jpg

All i got to do is find make an inlet manifold for them :)

In all ive got
Mbe 956 ecu
Wiring loom and vauxhall coil pack
A pair of weber 45 carbs
Trumpets
Air filters
And the throttle linkages although these will need a little machining to take the play out of them.

[freddy6868]

Well i have decided not to break the 170 barrier and jus smash the 200bhp barrier with a 2.3 bottom end conversion with a scorpio engine i might use the whole engine although if i use the 2l head with the 2.3 bottom end and it will have a cr of 11.8 which is alot :) have i lost it? The answer to that question i dont know.

http://i296.photobucket.com/albums/mm177/freddy686868/7d92c155.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/b8c74534.jpg

On another note the old engine and gearbox is all out.

http://i296.photobucket.com/albums/mm177/freddy686868/0e3c253d.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/9c80bf39.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/74eaa345.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/e3a92d6a.jpg

Scrap heap challage anyone?
http://i296.photobucket.com/albums/mm177/freddy686868/7be060a0.jpg

[mike77cos]

Quick work there

[freddy6868]

Quick work there

Yeah only took three hours tk get the engine and box out much easier than working than on a 106.

[freddy6868]

Well i thought i would use my 'old' fiesta to lug its 'last' engine from the local scrap yard in the for of a 2.3 scorpio I4 engine and find yet more room in my sheds for another engine. Although it will have another engine in it for luke before i part ex it in friday.
here she is
http://i296.photobucket.com/albums/mm177/freddy686868/5c8fcb07.jpg
As you can see in auto form so shes had an easy life
http://i296.photobucket.com/albums/mm177/freddy686868/3246e909.jpg
Stripped down the 2.3 and it has a couple of snapped exhaust studs in the head but nothing i can't handle.
So the 2.3 found a place next to it's little sister the 2.0 and that is the bottom shed full with 3 engines an engine crane and other random shite. Although the loved x flow is on its way to a new home tomorrow so ill have a little more room
http://i296.photobucket.com/albums/mm177/freddy686868/9eca2027.jpg
Now for the top shed. The contents are a 5speed type 9 box, 4speed mex box, mk5 escort gearbox, peugeot gti gearbox and a spare 106 gearbox casing. Along with other escort related rubbish that i have collected during my short term escort ownership.
http://i296.photobucket.com/albums/mm177/freddy686868/ff67a797.jpg
On a happier note i i ordered a 5 speed quick shift for the 5 speed and a wcxm to mount the engine from rally design yesterday and they turned up at my door today. So WHEN the weather is nice friday i will be fitting the wcxm along with the engine and box to measure up how much roiom there is and where everything has to go.
http://i296.photobucket.com/albums/mm177/freddy686868/dd0c63bf.jpg

[freddy6868]

My quick shift all built up.
http://i296.photobucket.com/albums/mm177/freddy686868/934ca92c.jpg

The new wcxm with the lower rack mounts against the old x member.
http://i296.photobucket.com/albums/mm177/freddy686868/d44ee17b.jpg

The engine and 5speed box is going to be trail fitted friday so i can see how much the pinto wcxm engine brackets need cutting and chopping. I cant wait!

[freddy6868]

Well after yesterdays failed atempt at getting the engine and box in place. I thought i would give it ago again today and i am pleased with the results.

Engine and box roughly in place for a quick measure up.

http://i296.photobucket.com/albums/mm177/freddy686868/b848d07a.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/e503720b.jpg

Bulkhead clearence!!!!!
http://i296.photobucket.com/albums/mm177/freddy686868/2f3789c0.jpg

Rad fits nice too
http://i296.photobucket.com/albums/mm177/freddy686868/9086b4b8.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/0c325a40.jpg

Pressed metal part of sump removed to clear the x memeber so ill have to chop that for it to fit.
http://i296.photobucket.com/albums/mm177/freddy686868/9d985095.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/f030d271.jpg

Pinto engine mount is just the right length just needs a new plate welded on to it for the bolt holes.
http://i296.photobucket.com/albums/mm177/freddy686868/aabc0630.jpg

Carb clearence
http://i296.photobucket.com/albums/mm177/freddy686868/3e7c725e.jpg

Im going to use the flange off the rs2000 and make a 1 1/2"-2" thick plate to bolt the original rs2000 flange to the 45"s

http://i296.photobucket.com/albums/mm177/freddy686868/ead32442.jpg

[Mark M]

been a great read so far.
keep it up. :cool:

[freddy6868]

Oooo some new bit and bobs for the escort.
My much needed oil cooler

http://i296.photobucket.com/albums/mm177/freddy686868/c7baca4d.jpg

Hid kit with new lamps

http://i296.photobucket.com/albums/mm177/freddy686868/c4b6fd3a.jpg

Coilovers with brand new tarmac billies in and i have a set of nearly new gravel spec dampers too.
http://i296.photobucket.com/albums/mm177/freddy686868/459d4588.jpg

Brand new strut tops fitted to the coil overs too

http://i296.photobucket.com/albums/mm177/freddy686868/688dd046.jpg

And a cheeky photo of my new car :-)

http://i296.photobucket.com/albums/mm177/freddy686868/a523efb5.jpg

[SHIFTY]

coming on well!, keep at it :cool: :thumbright:

[freddy6868]

Well i have all the gear anyway just got to kick my engineering head in to first now and trundle through it all.

More top quality parts at a discounted price for the bloody thing!

http://i296.photobucket.com/albums/mm177/freddy686868/6162034a.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/d4a8a127.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/8f0be209.jpg

I think im going to fit a hydraulic clutch aswell. As all the areoquip goodrich hoses are there to do so. Also all the braided pipes for front brakes.

And my billie gravel inserts

http://i296.photobucket.com/albums/mm177/freddy686868/a1660a94.jpg

[bluevan1]

good progress so far.
looks a major job there

[freddy6868]

good progress so far.
looks a major job there

Yeah its a bigger project than i thought!
More uPdates.

Well i've done some work on the escort yesterday and that was to install the bias pedal box and tidy up the hid wiring. It also involved doing something i hate doing and that is drilling holes in my cars. I ran all the front lines installed the pedal box and and bolted up all the ballest boxes for the hid units in the wheel arches. I done this as i want the van to look period and un-modern from the outside and have modern twist on the inside ;-P.

http://i296.photobucket.com/albums/mm177/freddy686868/c9cbc330.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/055f5eb6.jpg

I fitted up a strut to see if my 13x7 inch capri wheels will fit and it looks good!
http://i296.photobucket.com/albums/mm177/freddy686868/80a88569.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/8d97e007.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/eb143f2c.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/557c1132.jpg

The holes i had to drill in the shell :-S
http://i296.photobucket.com/albums/mm177/freddy686868/e558ac68.jpg

My in car bias adjuster
http://i296.photobucket.com/albums/mm177/freddy686868/1566abd4.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/c4f42fe2.jpg

The new briaded lines to replace the old flexy pipes.
http://i296.photobucket.com/albums/mm177/freddy686868/086288ef.jpg

[freddy6868]

Well the engine is all in one peice now with the rs2k cams and a new timing kit which includes timing chain,tensioner runner, hydraulic tensioner and all the seals to seal the front covers.
I have finished machining the engine mounts now just need to make four holes in the mounting plates get them welded together. Then it is just a case of finding some 45/50mm tube to fit the engine mounting plates to the part that bolts to the wcxm.
http://i296.photobucket.com/albums/mm177/freddy686868/98736f8a.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_1383.jpg
then once the engine is mounted i can figure out if i have cut the right amount out of the sump so it can then be welded up too.
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_1413.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_1415.jpg
I have also got carried away on ebay recently as i have bought a NOS lucus sealed beam reversing lamp for something like £6 posted! With no more than a couple of scratches on the back of it.
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_1410.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_1412.jpg
Another ebay bargin was these Cibie Super Oscars from the 80's! At £18 posted how could i say no. So i have cleaned them up today and the chrome work is in decent nick but the lamps are mint. the backs need a good strip back and a good paint and they will be like new. I bought some brackets off ebay with smaller lamps too (£2.99 +P&P bargin again!) so i will be going with the 2 up 2 down set up like the rally cars do.
left one is all polished up
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_1398.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_1401.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_1395.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/IMG_1408.jpg
the list now stands at
make a hydraulic clutch boss
fit the engine and blox
make the engine mounts
custom exhaust manifold (Tony Law jobbie)
inlet manifold for the webbers made by the bogg bros
fit the rad and wire up the fan
plumb up the water system
rebuild the front callipers
get the ignition mapped
I want all this done by the 17th of September too as i want to make rally day at castle coombe

[freddy6868]

the list now stands at:-
make a hydraulic clutch boss. F%&* it going to buy a retro ford one
fit the engine and box. Fitted although the engine has to come out again 14/08/11
make the engine mounts. Mounts completed! Just got to paint them 17/08/11
custom exhaust manifold (Tony Law jobbie). Booked in for the 12/09/11
rebuild the front callipers front calipers. Stripped to bare metal, painted and built up with a new seal kit 16/08/11
fit the rad and wire up the fan
Finish the sump mods
plumb up the water system
find a DOHC sierra starter
get the ignition mapped
inlet manifold for the webbers made by the bogg bros
Well on Sunday thanks to Curl, his old man and a couple of toilet roll tubes??? The engine mounts were made in-situ on the van and tack welded the best we could.
http://i296.photobucket.com/albums/mm177/freddy686868/bd549210.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/efa11658.jpg
They have been all tig welded up now! and i will get them painted soon. When that is done i will mount the engine, mod the sump finally and then measure up for inlet so i can get the bogg bros to make one up.
I rebuilt the calipers last week. Pulled them all to pieces shot blasted all the rust off them painted them up nice and built them up all with new seals. When i seen the pistons i thought they were shot but luckly they cleaned up lovely and the build up nice.
http://i296.photobucket.com/albums/mm177/freddy686868/0fab44c2.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/c38b6187.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/4fde11ad.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/ec113c0c.jpg

[freddy6868]

Well the engine and box have been fitted and the engine mounts are spot on although the gearbox mount needs to be moved 10mm towards the drivers side as the person who drilled the holes for the original 5 speed mount drilled them ****ed. I have cut up the sump to the correct size and need to find some sheet metal to fill the big hole i cut into it.

Mounts completed

http://i296.photobucket.com/albums/mm177/freddy686868/e305fc5f.jpg

Mounts fitted

http://i296.photobucket.com/albums/mm177/freddy686868/c411363d.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/e1a49944.jpg

No jacks or engine cranes here!

http://i296.photobucket.com/albums/mm177/freddy686868/3c84f9d6.jpg

http://i296.photobucket.com/albums/mm177/freddy686868/92d5dbd3.jpg

Prop checked to make sure it went into the box far enough which as far as i'm concerned it does, so happy days!

http://i296.photobucket.com/albums/mm177/freddy686868/8964e9a4.jpg

The engine angle in the bay which is just over 4 degs which i thought was pretty level with a 5 speed on the arse of it. I was worried about the carbs not working at this angle but i have been reassured by someone in the know thwy will work fine!

http://i296.photobucket.com/albums/mm177/freddy686868/a5366a85.jpg

Finally it's on her wheels for the first time in 7 months ( i think it's been that long any way) on her new coil overs too :-)

That was all fridays progress along with a load of measurements that had to be taken to make sure everything was going to work out fine.

Sundays progress was to pull it all back out attach the flywheel clutch and bell housing to the box and check if my hydraulic clutch set up from retro ford needed to be spaced or not. Which i'm happy to report is a straight bolt on jobbie! meaning all i need to do is drill two holes for the hydraulic lines in the bell housing and get it all painted up. Being done this week.

http://i296.photobucket.com/albums/mm177/freddy686868/d32c3ce8.jpg
http://i296.photobucket.com/albums/mm177/freddy686868/d0c1de7f.jpg

[mike77cos]

Proper progress there mate

[freddy6868]

Proper progress there mate

It is fair play i'm really cracking on although it is all too little too late as i have missed the show season.

With only 18 days untill the exhaust is being fitted i am pushing my luck to get it all finished by the 12th.

Another little update any way.

Tried the starter on the type 9 bellhousing and as you said it bolted straight up! Thats worry one over with. I also might have a fwd 2l escort one in the shed so i hope that will fit as the twink starter i have borrowed.
http://i296.photobucket.com/albums/mm177/freddy686868/6d956275.jpg
I also milled out and blended back the ribs in the sump that were in the way of the starter si it should bolt to the bell housing with out them being in the way.
Modded side
http://i296.photobucket.com/albums/mm177/freddy686868/5906df40.jpg
Original Side
http://i296.photobucket.com/albums/mm177/freddy686868/581f3959.jpg
Starter roughly where it is going to sit
http://i296.photobucket.com/albums/mm177/freddy686868/1af88cb9.jpg
The flywheel is in being lightened and all the uneven casting removed from the back and the bell housing is in for a lick of gloss black.
All i need to do now is make up a little plate to fill the hole in the little sump pan and the engine and box can go back in.
That is after i get all my brake and clutch fittings from rally design as i need to pipe up the slave cylinder for the clutch.

[freddy6868]

Well i'm really happy with how things have advanced in the last week as i have turned around all the parts need to refit the engine and box for the final time may i add.
Bellhousing degreased drilled and painted up
http://i1212.photobucket.com/albums/cc457/freddy6868/a378bd7c.jpg

All my brake/clutch lines and my slave cylinder all apart from one fitting!
http://i1212.photobucket.com/albums/cc457/freddy6868/9b7adc8c.jpg

Sump mods from A-B
http://i1212.photobucket.com/albums/cc457/freddy6868/768340a0.jpg
Cardboard before metal, measure twice cut once
http://i1212.photobucket.com/albums/cc457/freddy6868/8d0ac0e0.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/181f07a8.jpg
Welded up
http://i1212.photobucket.com/albums/cc457/freddy6868/fda637b4.jpg
painted up
http://i1212.photobucket.com/albums/cc457/freddy6868/95ce34c9.jpg

Side milled out off the sump to clear the starter motor
http://i1212.photobucket.com/albums/cc457/freddy6868/22b58737.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/1ba00f88.jpg

Yet another set of cibie super oscars :-)
http://i1212.photobucket.com/albums/cc457/freddy6868/1fd1313f.jpg

Flywheel all lightened!
http://i1212.photobucket.com/albums/cc457/freddy6868/42b5049b.jpg

[freddy6868]

Oil pump chain all connected up
http://i1212.photobucket.com/albums/cc457/freddy6868/bc1f19a2.jpg
Sump bellhousing and starter all fitted to make sure it all fitted which i'm happy to report it does.
http://i1212.photobucket.com/albums/cc457/freddy6868/6975b05c.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/9c3b94d2.jpg
Starter checked to make sure it will mesh the flywheel properly, which it does although the flywheel is very close to the bellhousing!
http://i1212.photobucket.com/albums/cc457/freddy6868/206fa4d6.jpg
All the front braided lines are now fitted and the new callipers all i need now is some new brake pads and a fitting kit
http://i1212.photobucket.com/albums/cc457/freddy6868/72f51d2c.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/b4211d0c.jpg
The engine is now in the bay for the final time but i couldn't fit the gearbox as the hydraulic clutch needs to be spaced out as i messed up the measurements when i checked the fit of it.

[freddy6868]

Well it has been a while since i wrote something on the blog and that is because not a huge amount has happened as i have relised the project as a whole can not be finished by THIS monday. But it has resided to a new home and that would be my mates garage over the weekend so i can do a little work on it. I have to seal up the inlets and exhaust ports in the head to slop shite getting in there and fit my new oil cooler set up alnog with my custom made titaniun oil cooler fitting tube thing :-P

The old one on the bottom clearly wasn't long enough or big enough in diameter to take the cooler. So i knocked this up out of some titainium bar that had lost its tracablity and was due to be thrown out.

http://i1212.photobucket.com/albums/cc457/freddy6868/4b5a005b.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/02a6e327.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/2ce3e7c1.jpg

On a final note the the engine and box never even need to come out again!
The list of things to do now stands at
Get the inlet made (with bogg bros now)
Get the manifold made (12-15/16th septemeber at tony law)
Fit and finish up thw wiring, ecu too
Mount coil pack and get leads
Mount rad and wire up the fan
Order up some water hoses and fit them
Bleed brakes and clutch up
Fit prop and quick shift
Fit fuel lines, webbers and the fuel pump
Get the bloody thing mapped and when it's up and running i'll buy it a road going prezzie of a nice tight plated diff.

[bluevan1]

good progress there m8 keep up the good work..

[freddy6868]

Inletmanifold completed by bogg bros and is in the post
manifold completed and fitted by tony law
Fit and finish up thw wiring, ecu too (this week 15/16th)
Mount coil pack and get leads (this week 15/16th)
Mount rad and wire up the fan (this week 15/16th)
Order up some water hoses and fit them
Bleed brakes and clutch up (clutch will be bled up this week 15/16th)
Fit prop and quick shift (easy, 15/16th)
Fit fuel lines, webbers and the fuel pump ( see what time i have left for the fuel lines)
Get the bloody thing mapped and when it's up and running i'll buy it a road going prezzie of a nice tight plated diff.

Well after an epic 700mile journey to leeds and back, forgeting my wallet, sleeping in a van two nights and getting a parking ticket coupled with the generator blowing mine and the mrs phone chargers and having no cig lighter for the sat nav i have an exhaust manifold fitted and a big grin on my face.

A couple of pictures of the manifold tony law made. And what a peice of art it is! You should see the way they make these pipes. Pretty much with a bucket full of sand and a heating element. I love the way that the front pipe goes straight back and the others curve out more and more to keep them the same length for when they meet.

http://i1212.photobucket.com/albums/cc457/freddy6868/9587bba0.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/f724fcee.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/c0fbb679.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/0b4524cb.jpg

[freddy6868]

Well i haven't said about this but i had a clearence issue with the 2.0l scorpio starter motor as the starter solinoid was on top of the starter which fould the engine mount and x member badly! So i ordered the 2.3 scorpio auto starter motor which originaly mounts on the drivers side. So when it is mounted on the passanger side the solinoid faces down missing the engine mount although it is very close to the lower part of the x member. Although everything about this conversion is tight everywhere which makes it a great challange.
http://i1212.photobucket.com/albums/cc457/freddy6868/f53bccd6.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/36e98250.jpg
Well my passanges is going to have hot feet as this is the exhaust to footwell clearence!
http://i1212.photobucket.com/albums/cc457/freddy6868/e8e4be3c.jpg
Some more shots of the mani as i'm so happy with it!
http://i1212.photobucket.com/albums/cc457/freddy6868/2a760569.jpg
All reinforced where they come out of the engine!
http://i1212.photobucket.com/albums/cc457/freddy6868/e5b2b8f7.jpg
Quick shift fitted, note the 4 speed gear knob fits and the original surround will fit too so it will look nice and stock. Which is the look i'm going for untill you open the bonnet.
http://i1212.photobucket.com/albums/cc457/freddy6868/b2e8e0f7.jpg
Scorpio alternator set up trial fitted although i might go for the rs2k set up as i can fit that on the exhaust side alot lower too.
http://i1212.photobucket.com/albums/cc457/freddy6868/d7bf9249.jpg

[freddy6868]

Fuel line run from the fuel pump to the engine bay all ready for when i get round to mounting the fpr.

http://i1212.photobucket.com/albums/cc457/freddy6868/597b56e9.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/96d5aff3.jpg

I'm going to hide the fpr and the ecu under the carbs to try and keep the bay looking fresh and tidy.

Rear brake lines all run through the car and i just need to conect the rear brake lines up.

http://i1212.photobucket.com/albums/cc457/freddy6868/1f034b9d.jpg

Exhausts all fitted up and welded up nice

http://i1212.photobucket.com/albums/cc457/freddy6868/18980731.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/78bc01d7.jpg

One piece prop all fitted up nice and snug in the tunnel

http://i1212.photobucket.com/albums/cc457/freddy6868/3d843acb.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/e596e7ac.jpg

[freddy6868]

Well i haven't updated my blog in a while but things are moving on great. I have re-wired the lights to work the HID kit with the help of my mate fatty who is a abit of a jack of all trades. Basically the main problem was i had tidied the earths all up into one and the lights, horn and other functions didn't work correctly. After that was sorted i set about getting the engine to turn over on the key which was quickly done by using a haynes manual of all things. All this was done on Saturday night and a few of the boys popped down to have a nose and it looked like this sunday morning when i got up to work on the escort with a nice hangover, ***e was the hangover cure by the way.
http://i1212.photobucket.com/albums/cc457/freddy6868/7ebeb561.jpg
I done a little shopping for some leads to fit my vauxhaul coil pack and ones that were the right depth for the cylinder head. I done this by sitting in halfrauds on the floor by the ignition leads and pulling them out of the box one by one untill i came up with these.
http://i1212.photobucket.com/albums/cc457/freddy6868/cc0255c1.jpg
i also think that is a good place to mount the new coil any coments on that idea guys?
Two holes made with a hole saw and them joined together by abit of filing gave me a nice size shaped hole in the front pannel to run the oil cooler pipes through.
http://i1212.photobucket.com/albums/cc457/freddy6868/ffd3e655.jpg
Oil cooler all in place and just need mounts made up to hold it in place
http://i1212.photobucket.com/albums/cc457/freddy6868/75f108c4.jpg
FPR all fitted and plumbed into the carbs finally ready to rock
I hid it under the carbs so when the air filters are fitted it will be hiden. The ecu will live there too just further back in the bay
http://i1212.photobucket.com/albums/cc457/freddy6868/ae192c78.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/9e45cc52.jpg
Trial fitted the rad although it needs some slight modding to get it to fit perfect
http://i1212.photobucket.com/albums/cc457/freddy6868/85e2780d.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/fcd2766f.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/8a9d556d.jpg
well after i couldn't really do any more on the engine conversion i got bored and decided to find out if my hunch was right and if so how bad were things under there.
I'll let the pictures do the talking
http://i1212.photobucket.com/albums/cc457/freddy6868/7c6b5a66.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/ebf2b3bd.jpg
classy a full repair panel over the rotten arch lip
http://i1212.photobucket.com/albums/cc457/freddy6868/4eeedf7a.jpg
2/3 sills on the rear of the arch
http://i1212.photobucket.com/albums/cc457/freddy6868/6bf90c02.jpg
Repair panel removed but the tack welds and filler remain
http://i1212.photobucket.com/albums/cc457/freddy6868/18676697.jpg
All the filler and most of the sport welds removed
http://i1212.photobucket.com/albums/cc457/freddy6868/89f0e1c0.jpg
All in all i was right that the sills and archs had been cowboyed in the past but it doesn't really bother me as i kind of worked it out after you had to really slam the doors shut and the tell tail signs of water pockets between the panels. I have also picked up a cracking welder/a welder for parts and a gas bottle for a tenner! so i will be tackling with a little nit of help my mate loffty who has just restored his mini.

[bluevan1]

lots of work done there m8
some mods cracking how u have fitted that engine.to a mk1 van a bet it will go some eh...:D
keep up the good work.

[freddy6868]

lots of work done there m8
some mods cracking how u have fitted that engine.to a mk1 van a bet it will go some eh...:D
keep up the good work.

These engines have only been fitted to a handfull of escorts but never an escort van that i know of and i like to be different so i fitted it with all the top parts.

Keep An eye on this blog though as i have started doing something else i have never done before.

[freddy6868]

Well luck is with me on this one as it is an easy repair. I have had the sills and arches in the back of the van for ages i just had to get round to doing them. So when i bought a 10 quid welder i decided to rip all the arches and sills of to see just how bad the damage underneath the new panels were and luckily its very localised.

So this i haw i done yesterday with the great help of my mate lofty who has just finished restoring and preping a mini for rallying so he has done alot of panel work.

We started of by marking out where we had to cut to fit the repair panel in. So we cut it a little bit short and trimmed away the excess to make the panel fit.

Cutting and trimming
http://i1212.photobucket.com/albums/cc457/freddy6868/9031a869.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/978aa291.jpg

Cutting done
http://i1212.photobucket.com/albums/cc457/freddy6868/c55c9862.jpg

Setting up/testing my new welder
http://i1212.photobucket.com/albums/cc457/freddy6868/3bf2357f.jpg

Cleaned up and covered
http://i1212.photobucket.com/albums/cc457/freddy6868/df03b660.jpg

All taked up inplace
http://i1212.photobucket.com/albums/cc457/freddy6868/5cee378b.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/f6ed8b8e.jpg

Seam welded 95% of the arch on but the gas regulator froze over so we had to wait a while for it to defrost

http://i1212.photobucket.com/albums/cc457/freddy6868/16f67269.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/a0ab73df.jpg

Whilst waiting for the valve to defrost we cut the sill off and found even more filler to hide the poor workmanship of the last guy. The whole rear of the van had coatings of filler like this in so no wonder it weighed in at 980kg with the old x flow in!
http://i1212.photobucket.com/albums/cc457/freddy6868/804d11e1.jpg

Welds all ground back and covered to stop them rotting
http://i1212.photobucket.com/albums/cc457/freddy6868/c7bf0839.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/1b180c2c.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/a6dbc14c.jpg

Only a couple more panels to do and she will be mint and solid once again!

[Aaron P.]

cracking on with it...looks great...wish mine was that far ahead :(...i need to get out to the garage more...:p

[freddy6868]

Well nothing has happened with the escort in months as i have bought a house and thw only time i touched the escort was to move her to her new garage. Which has no electrickery atm. I did buy some really wide wheels for her though!

I thought the wheels were 13x7" in size
http://i1212.photobucket.com/albums/cc457/freddy6868/e9feac60.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/77dde5e7.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/33ce2226.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/26caa595.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/9c3c0e68.jpg

But they are infact 13x8.5"! So abit wide for standard arches but it will work out fine.

Another reason why the escort hasn't had much attention is the mrs bought a capri so i am also working on that in my spare time so i have three projects on the go now. so all fun.

http://i1212.photobucket.com/albums/cc457/freddy6868/27026f97.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/fd31cb0d.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/5fe97efb.jpg

[Fat Cat the Rat]

Bought it off Ian and Neil then from Pontllanfraith !

[mike77cos]

Got to love a nice capri

[freddy6868]

Bought it off Ian and Neil then from Pontllanfraith !

What the capri?

[freddy6868]

Yeah its only got 78,000km on the clock so thats about 48,000miles if i'm right. It was only on the road 6 years and off the road for 19years, only had 2 owners too. So a lovely car for the mrs first classic ford.

[Fat Cat the Rat]

What the capri?

Sorry , yes i meant the Capri, use to live in the same town as them, as i rallied an Escort i used to pop in and buy odds and sods off them over the years.

[freddy6868]

Sorry , yes i meant the Capri, use to live in the same town as them, as i rallied an Escort i used to pop in and buy odds and sods off them over the years.

I don't know if they owned it originally i but i bought it of my mates grandfather who was from tonyrefail nr llantrisant and he bought it off a mate when the capri was 4years old as his mate crashed it and damaged the drivers side wing and slam pannel. Luckily the damage has been repaired and all it needs is some tlc to the pait and the original engine put back in.

[freddy6868]

I actually had time to work on the escort sunday! I helped a mate fix his starlet turbo on the saturday and had a free day sunday. So i spent 6 hours welding fresh metal into the body.
Firstly i had to remake the lip and weld that in. That was the easy bit and it didn't take up too much time.
This is how it looked before, too much missing metal for my liking.
http://i1212.photobucket.com/albums/cc457/freddy6868/3f7d6fe2.jpg

Well it took 4 and a half hours for me to make this peice of metal with a body work hammer, a peice of old worktop (to get the rad for certain parts of the pannel) and a bench vice to hold it all.

All tacked into the van
http://i1212.photobucket.com/albums/cc457/freddy6868/eca23d09.jpg

Abit of seam welding later and it was almost in
http://i1212.photobucket.com/albums/cc457/freddy6868/63ae6cc5.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/2e71ff46.jpg

I ground most of the weld back and welded up all pin holes left. But it was way too cold in the garage at this point to do any more so i just painted it up to protect it.
http://i1212.photobucket.com/albums/cc457/freddy6868/717bdb40.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/bdfcc2d3.jpg

The best bit of welding i done all day and i was lying on my back the horizontal weld that is.
http://i1212.photobucket.com/albums/cc457/freddy6868/a886aa1b.jpg

Well i had time to finsh what i started on saturday and i must say i am very impressed with my self as it's turned out well for a made from scratch pannel.

All welded up, ground back and primered and cavity waxed the inside to protect it from the nasties.

http://i1212.photobucket.com/albums/cc457/freddy6868/cc36fac6.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/6aaeca02.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/78d1ca23.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/c02b8a4b.jpg

Also my axle for my wide ass wheels turned up today. Only got to tack the leaf spring pans on it shot blast it and then get the seats tig welded on and to paint then.

http://i1212.photobucket.com/albums/cc457/freddy6868/a5680147.jpg

[freddy6868]

A little more has been done this week. Firstly i have cut out the passanger rear arch and welded a new one in, again took ages! I have modded the front pannel to take the oil cooler and i need to make a couple of brakets to hold the oil cooler. I also got round modding the ally rad as the outlets needed slight felting to take my engine configuration. I also splashed the cash this month as i have bought a nice plated Titan diff which after alot of thought i will be putting it in the 3.89 diff as it is in perfect working order already.

Looking good
http://i1212.photobucket.com/albums/cc457/freddy6868/20c41bda.jpg

Not so great
http://i1212.photobucket.com/albums/cc457/freddy6868/f25d21f4.jpg

Only a small repair patch needed here
http://i1212.photobucket.com/albums/cc457/freddy6868/2f64e556.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/203adefd.jpg

Peeling it off
http://i1212.photobucket.com/albums/cc457/freddy6868/e7f6abdb.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/8d716644.jpg

All welded up
http://i1212.photobucket.com/albums/cc457/freddy6868/9503ee5d.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/0dc28dcf.jpg

I have also solved the problem of how to mount all my little clutch, front and back fluid bottles to the car with a sugestion from my bro so i knocked this up and welded it in.

http://i1212.photobucket.com/albums/cc457/freddy6868/28d7bc20.jpg

[freddy6868]

This turned up in the post this morning! It was brand new second hand.
http://i1212.photobucket.com/albums/cc457/freddy6868/dded27fe.jpg
It wasn't planned to go out and buy a plated diff but this came up cheap and for once i had spare cash to buy it.
http://i1212.photobucket.com/albums/cc457/freddy6868/aa718d8c.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/99111732.jpg
All fitted with the help of my mate reedy. The diff was in good condition with only 0.008" of backlash and the CWP mesh was correct as it came out of a low mileage 1600cc mk2 escort only 30,000 miles on it. All steam cleaned and the new diff all fitted up it only took 25 mins to remove the old one and refit the new one then tweek side wheels to get the correct backlash again.
http://i1212.photobucket.com/albums/cc457/freddy6868/bbfc90ef.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/253d7998.jpg

[mike77cos]

Good find

[freddy6868]

I have also changed the fpr for the filter king with the 85mm bowl with the high flow filter as the old one seamed to have failed. The new fpr even has a built in pressure gauge so so you can set the pressure correctly.
Well as my old MBE wasn't mappable by anyone in the south wales area i sold it on the bay. Then i went out and bought a DTA S40 that will control injection aswell as the ignition as i think i will either convert the webers to run as throttle bodies or run throttle bodies in the future.

I then had to set about making a wiring loom for the lot and after a lot of advise off a couple of mates i dived in and expanded my skill sets futher. After getting my hands on some top quality wire and all the plugs and plug boots i set about making it. Below is a picture of the loom half finished as i haven't got heat shrink thick enough to go over some of the wires so i will finish it when that arrives.

I am happy with the way things have turned out as i even went as far as making litlle lables and heat shrinking them into the loom. I also think the black and grey is a good contrast.

After looking everywhere for a cheaper solution i had to fork out for a brand news tps sensor fo fit on the webers as i am going to run the engine on a 3D map untill i run it on injection.

I then relised i will have to weld in a lambda sensor boss into the exhaust system to get it mapped so i will get that welded in some time this week. I am happy to say the quality of the one i got was better than the one in the picture too!

[freddy6868]

I have also changed the fpr for the filter king with the 85mm bowl with the high flow filter as the old one seamed to have failed. The new fpr even has a built in pressure gauge so so you can set the pressure correctly.

Well as my old MBE wasn't mappable by anyone in the south wales area i sold it on the bay. Then i went out and bought a DTA S40 that will control injection aswell as the ignition as i think i will either convert the webers to run as throttle bodies or run throttle bodies in the future.
http://uploads.turbosport.co.uk/getrempic3.php?url=http://i1212.photobucket.com/albums/cc457/freddy6868/ce70b86c.jpg
I then had to set about making a wiring loom for the lot and after a lot of advise off a couple of mates i dived in and expanded my skill sets futher. After getting my hands on some top quality wire and all the plugs and plug boots i set about making it. Below is a picture of the loom half finished as i haven't got heat shrink thick enough to go over some of the wires so i will finish it when that arrives.
http://uploads.turbosport.co.uk/getrempic3.php?url=http://i1212.photobucket.com/albums/cc457/freddy6868/88dd113f.jpg
I am happy with the way things have turned out as i even went as far as making litlle lables and heat shrinking them into the loom. I also think the black and grey is a good contrast.
http://uploads.turbosport.co.uk/getrempic3.php?url=http://i1212.photobucket.com/albums/cc457/freddy6868/c96f5334.jpg
After looking everywhere for a cheaper solution i had to fork out for a brand news tps sensor fo fit on the webers as i am going to run the engine on a 3D map untill i run it on injection.
http://uploads.turbosport.co.uk/getrempic3.php?url=http://i1212.photobucket.com/albums/cc457/freddy6868/TPS.jpg
I then relised i will have to weld in a lambda sensor boss into the exhaust system to get it mapped so i will get that welded in some time this week. I am happy to say the quality of the one i got was better than the one in the picture too!
http://uploads.turbosport.co.uk/getrempic3.php?url=http://i1212.photobucket.com/albums/cc457/freddy6868/bung.jpg

[freddy6868]

Wiring loom was all finished last night and i have fitted it today. Hopefully the engine will be up and running tomorrow as my mate is coming up to set up all the ecu settings and get the engine up and going.
http://i1212.photobucket.com/albums/cc457/freddy6868/44657f66.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/877bde25.jpg
All the wiring that goes under the dash and the relays for the ecu and fuel pump. This loom isn't so pretty but it is solid and will do the job great.
http://i1212.photobucket.com/albums/cc457/freddy6868/d18f1924.jpg
I also measured how far the end of the axle it is to the spring pan and how far it was from the diff flange to the floor. This was so i could fit the anglia axle at the same 4 degree angle as the standard escort angle. That is also the angle of the engine and box. I measured the length of the anglia axle and from what i can remember it is just over an inch shorter each side. So i tacked up the spring pans and asked my mate coidy to weld them onto the axle fully as my welder wasn't up to the job.
http://i1212.photobucket.com/albums/cc457/freddy6868/921e34b2.jpg
The spring pans all welded up so the axle is ready to be fitted up. I'll do that Thursday morning fit the axle my plated diff and one piece prop.
http://i1212.photobucket.com/albums/cc457/freddy6868/05c8f86c.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/29a559ad.jpg

[Mark M]

your doing well.. keep em coming. :)

[freddy6868]

your doing well.. keep em coming. :)

Big update soon as i haven't had time to update the blog. So watch this space over the weekend. :jumpy:

[freddy6868]

The engine is all up and running thanks to my buttie kiwi who set the dta s40 up for me and calibrated all the sensors to get the engine up and running.

http://i1212.photobucket.com/albums/cc457/freddy6868/ef30bd0d.mp4

Well my 8.5j wheels fit in the arches with loads of room! I don't know why people say it is some impossible all the time.

http://i1212.photobucket.com/albums/cc457/freddy6868/83d360f8.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/58fd6eb0.jpg

I think it looks sweet as in this picture!

http://i1212.photobucket.com/albums/cc457/freddy6868/d6976cb4.jpg

Had and atlernator belt off my mate ginge who works in the local motorfactors. I gave him the dimensions and he got the right one straight off the shelf! Couldn't believe my luck.
http://i1212.photobucket.com/albums/cc457/freddy6868/026eab2c.jpg

[freddy6868]

well loads has happend in the last couple of weeks. So much that i haven't had time to update my blog. So here we go.
Last minute i changed my coil pack set up and thought it would be much neater to put the coils in the head like they should be.
http://i1212.photobucket.com/albums/cc457/freddy6868/6c981054.jpg
I also had my spare rocker cover painted in the same royal blue as my brake calipers and cibie lights.
http://i1212.photobucket.com/albums/cc457/freddy6868/af9587cf.jpg
Made up all the coolant pipes, even the ones for the heaters
http://i1212.photobucket.com/albums/cc457/freddy6868/pipes.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/3ca676d6.jpg
before
http://i1212.photobucket.com/albums/cc457/freddy6868/f9e37f03.jpg
after
http://i1212.photobucket.com/albums/cc457/freddy6868/936c02c7.jpg
Some flames from where she was started up first off
http://s1212.photobucket.com/albums/cc457/freddy6868/?action=view&current=147c3303.mp4
Out and about with my bros 205 the first time the escort had moved out of the garage under it own power
http://i1212.photobucket.com/albums/cc457/freddy6868/ec755ecd.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/0c24a49d.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/51d72335.jpg
ECU all mounted in the glove box out the way
http://i1212.photobucket.com/albums/cc457/freddy6868/8c54e55a.jpg

bonnet all fitted ready for the rolling road set up
http://i1212.photobucket.com/albums/cc457/freddy6868/e51172f5.jpg
All ready to be towed by the french box for mapping and carb tweeking
http://i1212.photobucket.com/albums/cc457/freddy6868/2f12a9b3.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/bc476f42.jpg
On the rollers
http://i1212.photobucket.com/albums/cc457/freddy6868/1417b925.jpg
Well we got to the rollers with out a problem even thought the towing van was a pug. So mosely set about doing the first run to check all the carb settings the ignition timing ect ect. After that was done a quick power run was done to check fueling and the power output. This wasn't happening though as the carbs were leaning out.
So after the carbs were fueling better the first ral run was done to find out the power output was a low 170bhp but he said it started wheel spinning at around 100mph so the van was strapped down and the figure shot up to 188bhp. After this run the floor cought FIRE! all the wax oil had melted off the floor onto the manifold and set the escort on fire.
A couple of videos from the power runs/mapping runs
http://s1212.photobucket.com/albums/cc457/freddy6868/?action=view&current=cb17be7d.mp4
http://s1212.photobucket.com/albums/cc457/freddy6868/?action=view&current=5ebf0d0e.mp4
http://s1212.photobucket.com/albums/cc457/freddy6868/?action=view&current=b93eba34.mp4
After a few small oil leaks and some water leaks the mapping was finished and the van made 191bhp @5.5k and stayed at that power the more it was revd. I think this is because the exhaust diameter is too small as this spec of engine should smash the 200bhp mark. It also made around 205 ft/lbs of torque @ 3K!
http://i1212.photobucket.com/albums/cc457/freddy6868/b9adb788.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/6642d437.jpg
Aswell as making the power the engine also drives lovely too it is like a normal car up to 1/4 throttle after that it just goes wild and pulls like a train.
After getting the van home i checked everything under the bay and relised that after the seroius heat the setting up had caused in the bay that a few items had started to melt!
http://i1212.photobucket.com/albums/cc457/freddy6868/49a2a21e.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/cf3242ad.jpg
Not to worry though as it shouldn't happen again as when on the move the airflow should give better engine bay cooling than the fans on the rollers.
All that is left to do now is tidy up everything and weld up the floors and put a new sill on it. Not long now and she'll be on the road! Now ther pressure is on though as there is only 37 days untill we leave for germany.

[SHIFTY]

Coming on great, gotta love a mk1 van :cool:

[lynx]

good work

impressed with engine conversion, the i4 dohc always seems to be wrongly underestimated conversion.:)

[freddy6868]

Well after a quick spin around the block i wasn't happy with the old disks and a standard set of pads so i went out and spent a couple of pennies on a set of mintex 1155's and a set of vented and grooved disks.
http://i1212.photobucket.com/albums/cc457/freddy6868/8087e982.jpg
All fitted up
http://i1212.photobucket.com/albums/cc457/freddy6868/728d695e.jpg
Next up was to work out why my lights didn't work but that was because the 12v+ feed to the main beam was loose so thats another task to knock off the MOT list
http://i1212.photobucket.com/albums/cc457/freddy6868/b1649609.jpg
Then i tackled the sill along with my mate Loffty as i wasn't happy to fit the sill on my own as it's such a long pannel it has to go on perfect as it ruins the look of the car. It took us a lengthy 5 hours to tack the sill up and towards the end the gas ran out but we didn't relise at the time as you'll be able to tell by some of the welding.
http://i1212.photobucket.com/albums/cc457/freddy6868/fbefb0bd.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/2e90d2bb.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/5fa241c2.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/3370de77.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/d21c06d3.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/901ba36f.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/2cebbae4.jpg
There are some holes along the roof seam which had just been filled with filler and painted over before so i havd a go at welding them up and grinding them back with great sucess.
http://i1212.photobucket.com/albums/cc457/freddy6868/18cca17a.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/7842cd2c.jpg
ground back and painted
http://i1212.photobucket.com/albums/cc457/freddy6868/a2bc1e99.jpg
a list i have written up to help me finish the van ready to go on the road, although this list gets bigger everytime i cross something off but i'm getting there
http://i1212.photobucket.com/albums/cc457/freddy6868/b22ebc3e.jpg

[freddy6868]

good work

impressed with engine conversion, the i4 dohc always seems to be wrongly underestimated conversion.:)

Yeah i have found only negative coments about the I4 (unless you own a mk5 rs2k) and alot of people don't believe the power these units put out in 'standard' form. Another common roumer is that the I4 is heavier then the weezy old pinto and after picking up a valver and a pinto i can safely say the pinto is heavier!

[freddy6868]

I also had to make up a little something for the passanger side indicator because when i took it apart some months earlier all the internals were rotten and fell apart. So i knocked this up in my break today.
http://i1212.photobucket.com/albums/cc457/freddy6868/aa9858f8.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/cfa0494b.jpg
http://i1212.photobucket.com/albums/cc457/freddy6868/2b5ff655.jpg

[freddy6868]

Failed mot with stupid things like missing split pins locked passanger door no washers and other minor issues but shes goi g in for a retest tomorrow.

No big updates really just that i have been for a sneaky skid down the ocal industrial estate and i love the thing! It is mental and i haven't even taken it out in the rain yet :-S but you can drive it like a normal car when you need to then. A few photos of her all 'finished'

This list is now finished thanks to the help of my mate marc who is mk2 escort bonkers.
http://i1212.photobucket.com/albums/cc457/freddy6868/935a6e3a.jpg

Heat proofing to protect the wiring and it's doing a great job so far too!
http://i1212.photobucket.com/albums/cc457/freddy6868/7f567a4f.jpg

My bros 205 is in the garage so shes back out in all weathers for now to prep her for the hard times to and fro germany
http://i1212.photobucket.com/albums/cc457/freddy6868/1612a9d0.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/16ad60af.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/5c54a7c6.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/063d22c0.jpg

Some sponsorship from the boys
http://i1212.photobucket.com/albums/cc457/freddy6868/407ecd1f.jpg

F&M motorsport stands for fred and morse as we have built the thing from scratch
http://i1212.photobucket.com/albums/cc457/freddy6868/3d7e998e.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/ca385f00.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/0bcdd726.jpg

http://i1212.photobucket.com/albums/cc457/freddy6868/d83e0b31.jpg

So thats it so far she rough and ready with plenty of get up and go so its all fun and games now.

[Aaron P.]

its come along way since you bought it, looks good on them wide rims but get a lower profile tyre i wreckon,

how does it handle and power etc??? i take it it eats jiuce :D

whats the plans on colour????

id say your well happy the bulk of the build is now over :cool: and same with your missus