My flat front RS build (not rebuild!!)

[mk1rally]

After a bit of mythering, thought I'd grab some time (its too cold in the garage -4!!) to post some photo's of my build.

I'll make no appologies, this is a build of a originally very knackerd RS2000 to the road, in fact the original car was so knackered, I reshelled it, arched it, changed the colour and intend to enjoy it.

RS police - Before you moan about restoring it, it wasnt economical to do so. It was a rally car, had a very hard life and TBH, you could have easily sunk 20k sorting the shell out with NOS panels and paint/time. I have restored enough cars to know what I want from it and is important to me. A good strong shell is key, not years of continuely patching it up and I had my eye on a mint LHD one that would do the job. I do appreciate the originals too, and if you have one or one that can be recovered, that's great and you were lucky..I wasnt so lucky but it was what doable within my budget and what I wanted to do with the car. TBH, I would not have arched it or changed it's colour if it was a good example, as per my other car, my Mini. A few on here have seen that and will tell you it's a lovely rebuild.

I'm a firm believer of using them, not polishing them in the garage so a reshell was fine for me. If I ever sell it, I will be clear it was the case, not try and pass it off as its original shell. Its on print in here, see so I can be called on it!!

Justification over!!

Ok, so in my youth, my Dad and my Uncle both used to run cars in the motoring news championships, and local event's up here in the North West of England. I sent the 70's and early 80's brewing up, cleaning numbers, changing wheels, Driving service vans (sorry officer, only a few miles and I look much older than 15!!), refueling and general od jobs before getting to drive at a later date myself on Mull and the likes.

This Escort is to be built as a bit of replica of the cars they had, but not specifically the same. Mostly period bits and to be used for runs around here, track days and maybe some longer distance tour type stuff. This is because the RAC/MSA went and banned 4 chokes on a 4 pot engine, arches, non FIA/MSA dates stamped seat's/belts so there is not really a modern class for this car to compete in. I already have another car to do this anyway.

My uncle died last year of the big C and my Dad dragged the pictures out of those heyday's and said it would be good to do/have something like those old barking escorts again....so i decided that was a nice thing to do and its made my Dad (approaching his 70's) a very happy man and he can't wait to have a ride out in it!! It's lovely to see him excited.

Pictures to be uploaded

[alancdavis]

Look forwork to seeing the pics
I also competed in the MN events and recall the greats nights out on the likes of the illuminations and the RL Brown

[mk1rally]

Ok, so here's the shell as it started out.

http://farm8.staticflickr.com/7002/6821940917_bdd46da631.jpg (http://www.flickr.com/photos/46726182@N08/6821940917/)
022 (http://www.flickr.com/photos/46726182@N08/6821940917/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

It was a 96k kilometer (less than 60k miles) car from Northern Sweden. They dont use salt up there apparently and tend to only bring them out in the summer. It had a sump heater in it that you plugged into the mains to keep the oil warm and a additional plug that I can only presume was for a heater internally. Apparently it was a 1 lady owner and it showed. The trim was lovely and apart from a dented rear bumper, it was in geat condition with very little wear. It has the original ford tool kit, rubber mats, mud flaps, jack and bag.

The shell needed a small (2"x2") patch at the bottom of the tyre well and about the same size on a chip on the front off side wing. I cut out the rot and let these in, lead loading after to ensure a good seal. The rest of the shell was factory paint, even the underside had the chassis balck showing on the floor pans. It had/has a thick sealer in the arches that seams to done its job. Thats it.

The roof had peeled and had been painted with red lead to stop it getting worse until it was resolved, but not dented or rotten.

[mk1rally]

http://farm8.staticflickr.com/7001/6821942765_e7873ab664.jpg (http://www.flickr.com/photos/46726182@N08/6821942765/)
036 (http://www.flickr.com/photos/46726182@N08/6821942765/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

I'm sure this has been covered off before so I will show you a few of the progress shots.

After marking up and drilling the rear arches, I cut out the outer lip and the inner well to allow me to raise the height of the tub. The black line is the seam where the arch rivets to the body. The outer was cut level and in profile with the inner arch -10 mm which I then bent up carefully to make a lip to attach the new inner tub too. nerve racking stuff. My dad came down and talked me through it plus I surfed the net a fair bit too befor making the cuts!!

[mk1rally]

The arches were then etched and painted body colour before being seam sealled and rivited to the body. Helps stop disimilar metal corrosion.

I temp put on the new axle to make sure all was clear with the rims. Its a 3 ltr capri atlas with a ZF LSD, 4.6 CW and brace/skid. Built by the squires. Oh and it's still on drums for now!! This gave me the positions for the Panard tower and antitramp brackets (we are running a back seat as he did!).

I tacked these in place, took off the axle and welded them up proper. I also strenghthend the boot floor up where the tower comes through and mad a plate to cover it so it look right.

Back went on the old axles and wheels for paint.
http://farm8.staticflickr.com/7008/6821945121_7a2d17ba76.jpg (http://www.flickr.com/photos/46726182@N08/6821945121/)
028 (http://www.flickr.com/photos/46726182@N08/6821945121/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

http://farm8.staticflickr.com/7152/6821943861_83c8925894.jpg (http://www.flickr.com/photos/46726182@N08/6821943861/)
045 (http://www.flickr.com/photos/46726182@N08/6821943861/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

The trim holes were carefully welded up (min heat) with a copper bar behind them and etched.

[mk1rally]

This was it with the big axle on.

http://farm8.staticflickr.com/7174/6821942543_09d5e7aa10.jpg (http://www.flickr.com/photos/46726182@N08/6821942543/)
048 (http://www.flickr.com/photos/46726182@N08/6821942543/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[ModenaRS2]

Nice, love an arched MK2, keeps the pics coming:cool:

[mk1rally]

Everything was carefully stripped out of the car as some of it would be reused again (trim panels mostly)

I then got the turrets together. Now although the rounded ones look nicer, cars my dad and his mate's ran had square ones, they looked (too me) easier to fit and were cheaper!! I was quite happy to use that as a excuse!!

So I marked it up by using some diagrams from the squires and cut the inner arches and parcel shelf. Tacked the bases in and then with the help of a ratchet strap, got them in the right position/incline and welded them in place. I made small fillets for the parcel shelf area and tacked all that back together.

http://farm8.staticflickr.com/7164/6821935269_86f38683d7.jpg (http://www.flickr.com/photos/46726182@N08/6821935269/)
046 (http://www.flickr.com/photos/46726182@N08/6821935269/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

Once I was happy with that, i managed to get a RHD dash from GS Escorts (cheers Graeme) and cut out the old one. Along with the pedal box holes and steering coloum holes, we were ready to go after a clean out and final prep.

Andy at Newlook custom's convinced me he was going to move the pedal box strenthening plate and fill up some of the LHD holes.

It was loaded onto the trailer and taken to paint.

It was 3 months into the build, working 6-7 hrs a week and the odd day at the weekend.
http://farm8.staticflickr.com/7168/6821941965_ae427a4441.jpg (http://www.flickr.com/photos/46726182@N08/6821941965/)
058 (http://www.flickr.com/photos/46726182@N08/6821941965/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

http://farm8.staticflickr.com/7169/6821939743_0d7d3a5b27.jpg (http://www.flickr.com/photos/46726182@N08/6821939743/)
057 (http://www.flickr.com/photos/46726182@N08/6821939743/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[mk1rally]

I forgot to add, I added the RS specific panels to the shell and gusseted the rails, cut out for the rad and added the rad top panel and bottom. The shell was then welded up as per the escort prep book. I also cut out the rear valence to allow me to raise the back box a little.

Ok, whilst at Andy's he moved over the pedal box plate that's inside and welded up the old holes and made them good. Made good the areas along the sides where the chrome trims were and generally squared it all up.

The blokes a perfectionist and he spent a fair while sorting the swage lines and making sure the door, boot and bonnet fits were just so.

Once he had done that, he painted the inside of the doors, boot and bonnet, also the complete boot area and engine bay.http://farm8.staticflickr.com/7020/6821936737_b580978223.jpg (http://www.flickr.com/photos/46726182@N08/6821936737/)
067 (http://www.flickr.com/photos/46726182@N08/6821936737/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr
http://farm8.staticflickr.com/7029/6821934913_55db85ae1e.jpg (http://www.flickr.com/photos/46726182@N08/6821934913/)


http://farm8.staticflickr.com/7169/6821941241_178ef2f71c.jpg (http://www.flickr.com/photos/46726182@N08/6821941241/)
085 (http://www.flickr.com/photos/46726182@N08/6821941241/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr
066 (http://www.flickr.com/photos/46726182@N08/6821934913/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[mk1rally]

http://farm8.staticflickr.com/7175/6821945865_25031f5f8d.jpg (http://www.flickr.com/photos/46726182@N08/6821945865/)
086 (http://www.flickr.com/photos/46726182@N08/6821945865/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[mk1rally]

I've alwways like diamond white and it was the colour of my first and second escorts back in the day (it was 20 years since I've had one!!) so the shell being white anyway it worked out fine. The original RS was Red and then Black and then a few other shades at some point!! I dont think it was ever white!

I wanted to replicte some of the period schemes and not create a works replica, its been done and I love them but like I said, my Dad, uncle and chums never had anything so fancy.

I liked the flash on the Cossack cars and loved the colour of the 77 works ones. I ended up drawing a few pictures and colouring them in (a ideal thing to do with your 2 year old!!) and when I had a load of mates over for a meal, asked them to choose. Well the design was pretty much the one I would have picked and I simply handed this over to Andy with the colour codes and bit of a chat. When I got it back, I wasn't sure but its grown on me and I love it now the shell is coming together. A bit different but period enough, not to fancy.

My Dad said that they just masked them up and painted them, not flatting them off so there was no ridge between the colours and then I read that the works cars were hand painted, So that was good enough for me. So there is a ridge but that's ok. I did'nt paint the rear arch as it would have been less of a pain to change should it have been clipped (apparently).

http://farm8.staticflickr.com/7153/6821943309_19736914ea.jpg (http://www.flickr.com/photos/46726182@N08/6821943309/)
089 (http://www.flickr.com/photos/46726182@N08/6821943309/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr
http://farm8.staticflickr.com/7162/6821938705_1400885d72.jpg (http://www.flickr.com/photos/46726182@N08/6821938705/)
092 (http://www.flickr.com/photos/46726182@N08/6821938705/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr
http://farm8.staticflickr.com/7147/6821945753_88242bbda3.jpg (http://www.flickr.com/photos/46726182@N08/6821945753/)
091 (http://www.flickr.com/photos/46726182@N08/6821945753/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[mk1rally]

I got the shell back just after christmas. Took the old axle off and started on the underside at the rear. I scrubbed it back, added a coat of stone chip and 3 couats of white hammerite. Obviously masking off the top coat. same on the rear arches and some way on the back of the floor pans. Also where I replaced the diff panel (for the bigger pigs head)

http://farm8.staticflickr.com/7028/6821944881_4164da2e2e.jpg (http://www.flickr.com/photos/46726182@N08/6821944881/)
126 (http://www.flickr.com/photos/46726182@N08/6821944881/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

http://farm8.staticflickr.com/7020/6821933593_5cc31a83fb.jpg (http://www.flickr.com/photos/46726182@N08/6821933593/)
127 (http://www.flickr.com/photos/46726182@N08/6821933593/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

Once that was done, I bolted on the atlas axle and the new rims/tyres and spun it round ready for the front.

http://farm8.staticflickr.com/7174/6821944593_7477548737.jpg (http://www.flickr.com/photos/46726182@N08/6821944593/)
130 (http://www.flickr.com/photos/46726182@N08/6821944593/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

I love that angle!!

I did the same to the front arches and under the front foot wells. Then I built up the struts (cheers cossi si) with GP4 hubs, Willwood calipers (Cheers Louie/Mikethe panel) and bolted the whole lot up. Not a great photo, must have been a cold Iphone or me shivering!!
http://farm8.staticflickr.com/7035/6821943183_caaceef7a6.jpg (http://www.flickr.com/photos/46726182@N08/6821943183/)
137 (http://www.flickr.com/photos/46726182@N08/6821943183/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[mk1rally]

That cage has gone in but is not bolted down yet. It was to get it out of the way in the garage and I want to fit it when the engine is in place and the shell is stressed as it would be on the road (within reason). Next up was the wiring loom. I have the original LHD one and the original RS2000 one. Its been a bit butchered at some point but with a bit of thinking, I think I have sussed it. the connectors are not damaged and it doesnt seem brittle. I would have loved to replace it but they dont make them new due to the rubberised connectors (apparently). I had to bolt on my lamps because:

1. it gets me a bit giddy!!
2. gives me a idea where I want the extra wiring/relays for the additional loom I will have to make.
3. it gives me the opertunity to make brumm brumm noises when nowbody is listening!
http://farm8.staticflickr.com/7166/6821941525_f2b3c83034.jpg (http://www.flickr.com/photos/46726182@N08/6821941525/)
142 (http://www.flickr.com/photos/46726182@N08/6821941525/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

http://farm8.staticflickr.com/7142/6821937713_3848ee2035.jpg (http://www.flickr.com/photos/46726182@N08/6821937713/)
141 (http://www.flickr.com/photos/46726182@N08/6821937713/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

Ive got a fair few bits to go into it.

Nice Mike Stewart 2.0 pinto from mike the panel (RL22, twin 48's and gp 1 head) though I am considering a CNC head,
BGH type 9 box (still also got the original RS box too)
Export tank (my dad said he used Capri ones but I prefer the look and location of this one) cheers Andy.

On the inside I've got a set of Scheel RS1800 buckets and a standard rear seat (I used to ride in it as a kid on my dads!), Spingalex rim, Halda twinmaster, full set of carpets. Cheers Darrell.
I rember removing the carpets and trim out on a Friday afternoon before they went on event. When he was a bit short, it was the only car so he used to take me to school or take his tools to work in it (he's a retierd builder) other than that it was his company Snapes transit van (anyone remeber them, dark green?), brushed out and loaded up for the weekend!!

Once the electrics are sorted and I am making up alloy panels to relocate the fuse box inside, I'm onto the brake plumbing. Should be fun.

Hope you are enjoying the pics as much as I am enjoying the build.

[taffr]

that looks spot on, nice to see a freshly built car getting done, cracking job:cool:

[alancdavis]

looking good

[Dave1800BDA]

what a great job, very good,

lol at the heater and sump heater

[mk1rally]

Thanks Gent's, very much appreciated. It was the standard of some of the cars on here that has kept me making sure its going together ok.

That being said, I'm quite happy with constructive pointer's on what's the right way!!

I've been in the Historic Mini Cooper S world for a long time and I've lost touch with escorts. I have always wanted another one, it just took me a while and a push!!

And I'm really loving it. This is a keeper!!

[wetandwindy2]

looks nice this

[Skids]

Looking good Dave you are doing a cracking job,hope mine looks half as good when it gets painted in a few weeks .
Mark

[Mark M]

keep the pics coming, cracking job so far. :cool:

[bluevan1]

nice build there .

[cossie si]

Looks great :D;)

[mk1rally]

Thanks gents, the weather has eased up a bit here so I think I may be able crack on with the electrics tonight...getting twitchy not doing anything!!

I need to form a alloy panel to mount the fuse box in. Just under the dash on the passenger side so it's easy reachable. Then I need to extend the loom to it.

I bought a folder (machine mart had a vat free day and I've wanted one for a while) so I'll be messing up a perfectly good bit of alloy on that then tonight!!

[Mikethepanel]

Looks great that does dave!
If your getting twitchy not doing anything, theres plenty to do on my car! Lol i might even be able to borrow a heater aswell lol

[mk1rally]

Looks great that does dave!
If your getting twitchy not doing anything, theres plenty to do on my car! Lol i might even be able to borrow a heater aswell lol

Thanks for the offer Mike, can you just confirm your unit is surrounded by 100mm kingspan, heated and has 3 inch pile carpet??:):)....thought not!!

Hopefully a sparky mate of mine has offered me a blow heater thing to use (hopefully only for the next few weeks) so I can crack on. I drew the line at 5 layers and unable to move!!

I've got some bits to do on the Cooper S, ready for its first event this year in the begining of March. Times a ticking.....

[Warby]

Ya big wuss, we woke up to -38c here in Sweden on Saturday morning, now that's ****in cold!

The car's coming on well, you'll be up the road in a few weeks at this rate ;) We've been here just over three weeks and I've already managed to find a new MK2, not as good as the one I sold you but good enough for a rally car.

Keep the photos coming, if you can find your mittens that is ;)

[kas750]

Hopefully a sparky mate of mine has offered me a blow heater thing to use (hopefully only for the next few weeks) so I can crack on..

I have a spare propane space heater that you are welcome to borrow for a couple of weeks if you are stuck.

[mk1rally]

Ya big wuss, we woke up to -38c here in Sweden on Saturday morning, now that's ****in cold!

The car's coming on well, you'll be up the road in a few weeks at this rate ;) We've been here just over three weeks and I've already managed to find a new MK2, not as good as the one I sold you but good enough for a rally car.

Keep the photos coming, if you can find your mittens that is ;)

You chose to go to the land of snow!! nice to hear from you though mate.

Thought you may have been a frozen statue by now. Thanks for the comments too.

-4 or -38, its all the same to me. In my youth I spent a few lovely winters in Norway on Training. I was young and daft then!! Going out for early morning BFT's with the snot frozen to your face...now that is madness!

Thanks for the offer of the heater, if this one don't come off, I may well have to call you on that.

[mk1rally]

With the weather improving slightly (either that or I am getting numb about the cold) I cracked on with the wiring loom.

I decided to use the original RS loom but wanted to mount the fuse box internally on the passenger side dash for easy access. This would leave the original hole in the engine bay to run the brake pot plumbing through neatly too.

I had to fabricate a alloy panel that I could mount the original centre switches into and the fuse boxes (the one for the car loom and one for the aux. loom).

I used the original plastic centre part as a measurement for the replacement and made it full width across the dash. I've used riv nuts so that I can seperate it if needed for access. It secures underneath with the original locations on the blower/heater box and has a upstand on the back side to secure the loom to with P clips.

The alloy is still in its blue covering but the intention is to use black satin crinckle paint.

The Halda twin master will mount on a plate, secured via the factory holes in the Ghia replacement dash panel, above the fuse boxes. That way I can take it out when needed (the price of Halda's is madness nowadays!!)

Taken with a Iphone, but you get the idea.

http://farm8.staticflickr.com/7047/6861324181_599c13bca3.jpg (http://www.flickr.com/photos/46726182@N08/6861324181/)
IMG_0313 (http://www.flickr.com/photos/46726182@N08/6861324181/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

Just planning the switch arrangement. Using the original flasher and HRW switches but does anyone know if I have to use the fluid level check switch? is it a MOT requirement on a car as old as this (1976)??

[Davecos4x4]

great work you are doing. :)

[mk1rally]

Managed to finish off the alloy panels this week.

Bit slow as I have a event next weekend in the mini that it has to be made ready for. Just the odd job like checking the brakes, re-fit the sump guard, get the release agent off the new tyres and a general look over.

So back to the panels. Once I had decided where it was all going, I drilled and rivnuted the panels. Scotch brited them and gave them 2 light coats of etch primer. Once that had gone off I gave it the crincle paint treatment. Its come out ok and I did follow the instructions but its more lumps than crinkle TBH!! nice and even though so it looks like its right!!

http://farm8.staticflickr.com/7206/6895554107_6d7ea5ec91.jpg (http://www.flickr.com/photos/46726182@N08/6895554107/)
IMG_0317 (http://www.flickr.com/photos/46726182@N08/6895554107/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

Fitted it up to the dash rail and now I have the points to build the new loom too and where to fit the replacement fuse boxes. Will start that next week, progress on the mini permitting but should be fine now.

I also picked up the CNC head/cam from Rick Woods. Took a couple of photo's of that as well, looking to get that together soon too.

http://farm8.staticflickr.com/7193/6895556247_61904feaa9.jpg (http://www.flickr.com/photos/46726182@N08/6895556247/)
IMG_0319 (http://www.flickr.com/photos/46726182@N08/6895556247/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

http://farm8.staticflickr.com/7207/6895556061_ef5f6bd41c.jpg (http://www.flickr.com/photos/46726182@N08/6895556061/)
IMG_0318 (http://www.flickr.com/photos/46726182@N08/6895556061/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[mk1rally]

Finally finished the wiring loom and fitted up the dash with the original switches, aux switches (eventually turning up from Demon Tweeks!) and fuse boxes.

Now started on the brake plumbing and running the pipes/lines to the rear, inside.

http://farm8.staticflickr.com/7199/7044864687_f6d7cc2638.jpg (http://www.flickr.com/photos/46726182@N08/7044864687/)
dash (http://www.flickr.com/photos/46726182@N08/7044864687/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[mk1rally]

Brake plumbing and wiring loom in the engine bay.

Used the original hole for the LHD steering rack, and it throws the loom out of the way of the carbs (not alot of room around them)

http://farm8.staticflickr.com/7126/7044900753_31dfd640b2.jpg (http://www.flickr.com/photos/46726182@N08/7044900753/)
Engine bay (http://www.flickr.com/photos/46726182@N08/7044900753/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr


Gear stick moved back (original hole cut out around it and the material rear of it to enabe me to spin it around 180 deg and weld back in) Fits lovely.

BGH geartech Type 9 back in now (3rd time lucky!!) with a few little mods to the original gearbox mounts, original gear gaitor fits on ok. Dosnt bang on the body which would drive me mad.

http://farm6.staticflickr.com/5160/6898807030_b58873a12b.jpg (http://www.flickr.com/photos/46726182@N08/6898807030/)
inside (http://www.flickr.com/photos/46726182@N08/6898807030/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[andym]

Keep up the good work....saw this car about a month ago...:D

[bluevan1]

nice dash set up there .

[mk1rally]

Cheers, it took a bit of thinking about. Finding I'm doing plenty of that on this build (and TBH enjoying it too!)

Ok, managed to get the old head off the engine on Thursday night as I wanted to put on one of these CNC ones from Rick woods (pictures earlier in the thread).

Took the od one off and no horror stories to be found. Bores look well and not scored at all, pistons happy. The copper o rings in the block face were fine and looking at the old gasket, were doing the job well.

Gave the block and new head a lick of Satin black engine paint after cleaning it up and than once dried, lined up the new gasket and put the head on. Not tightened the head bolts too mush as want to get it in the car first and then I can torque them down properly.

Not installed one of these into a Escort for a while (like 20 years) and thought it would go in as easy as the crossflow came out.....nope wrong!!

I'd lined the engine bay with bubble wrap and wing guards to stop is scratching but the main problem (as you all prob know!) is that the crossmeber was in the way. Steep learning/remembering curve for me!

So out comes the block (carefully), one brew and 30 mins thinking time later, I drop the strut tops and crossmember and go for tea.

Back after a filling meal with time to ponder (but unable to wrestle about under the car due to said meal!!) I lowered the block in and bingo, it lined up with the box straight of and home.

Result!!

So here it is, home in its rightfull place.

http://farm6.staticflickr.com/5463/7063820141_cfa1cf17ff.jpg (http://www.flickr.com/photos/46726182@N08/7063820141/)
engineexhaustside (http://www.flickr.com/photos/46726182@N08/7063820141/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

48's off to the cleaners (I've took off the red paint by hand) and heat sheild/exhaust manifold next.

Now I know where all the additional plumbing/wiring is going, it should start to move on now.

http://farm8.staticflickr.com/7202/7063820241_3bc037b830.jpg (http://www.flickr.com/photos/46726182@N08/7063820241/)
enginein (http://www.flickr.com/photos/46726182@N08/7063820241/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[mk1rally]

Been getting a few things done now.

Managed to get the Tony Law manifold on, one I cleaned out the head threads. Seemed to be full of swarf from the the CNCing. Had to flex the manifold on a bit and then discovered it caught the standard cross member. 10 mins and air saw later, all clear.

Given it a coat of POR15 exhaust paint, seems to have worked on my other cars, not burning off in the first 10 seconds!!

http://farm6.staticflickr.com/5199/6930619912_e12d80aea7.jpg (http://www.flickr.com/photos/46726182@N08/6930619912/)
tonylaw (http://www.flickr.com/photos/46726182@N08/6930619912/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

I've used some DEi heat sheild on the mount and although it cant be seen here, on the leg and at the bottom corned of the inner wing. Also lagged the brake pipe too.

The clutch cable is almost touching though I did get one of those with heat sheild on. I may well look at what else I can do to protect it.

Its a nice thing that manifold, so it should be!!

Put the hoses on to get the clip sizes measured up and ordered. And also plumbed in the Rad and fitted the temp sendor for the front mounted fan.

Ordered a new oil catch tank and a replacement inlet gasket (as I ordered the injection one, to find that is bigger than the twin weber manifold at the top!!)

Really enjoying the build and seeings I've not got a cat in hells chance of getting on the Lakes tour due to it not being ready, taking my time.

http://farm8.staticflickr.com/7276/7076688831_bdef3ff062.jpg (http://www.flickr.com/photos/46726182@N08/7076688831/)
photo (http://www.flickr.com/photos/46726182@N08/7076688831/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

[kas750]

Nice work.Did you get in touch with Karas?

[mk1rally]

I did, cheers. They are very helpful and dropping the carbs off on Monday. My dads back, so should have that belt sorted for you on Wednesday all being well.

[kas750]

Good news about the carbs.It would be great if you could post some before and after pics.I am sure you will be really pleased with the results.

[mk1rally]

Got distracted recently, beginning of the season for the racing and some stage/road events plus upkeep on the rally car has meant me not spending as much time as I'd llike on the escort.

The mini has just come back from the rolling road and I had to retime the camshaft as the suppliers had given me the wrong figures...4 deg's retarded out!!

The Merlin FF was getting ready for Cadwell after a bit of a off last outing, nothing too bad but the Gaz shaocks needed rebuilding (so off they were sent)

Busy unit, easily distracted too!

http://farm8.staticflickr.com/7196/7135360989_b25600261b.jpg (http://www.flickr.com/photos/46726182@N08/7135360989/)
thegarage (http://www.flickr.com/photos/46726182@N08/7135360989/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

So back to the 'scort.

Got the carbs on to give me a idea how much space I have in and arround them. I then got the locations of the fuel reg and breather box sorted. I could then install the luminition too and make the looms the right lenght to not look untidy.

It seems to take an age to get it right. Last night I fitted the coil, made good the wires and mounted the ignition control box...2 hrs gone!!

It will be ready for the escorts 50th at this rate!

http://farm8.staticflickr.com/7188/6989276334_3dfcf010f4.jpg (http://www.flickr.com/photos/46726182@N08/6989276334/)
carbsin (http://www.flickr.com/photos/46726182@N08/6989276334/) by jerrythegerman (http://www.flickr.com/people/46726182@N08/), on Flickr

The fuel line now runs above the chassis rail and not as in this picture. I was looking at running it along the wing but thought not.