Mk2 2.3 Duratec

[RS2000&MEXICO]

thats a good looking car m8...:cool: :D

[GAZ W]

that car is perfect in every way :cool:

[Aled]

Unbelievable !....cracking work :wav:

[redracer]

Hi

First some pics of the car



http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Mk2_Pic7-1.jpg



Only catching up with this thread now, top class work there :cool: . May I ask how your front spoiler works with the arches ? Is the spoiler glass fibre with the arches moulded in ?

CheeRS

[John Hall]

Only catching up with this thread now, top class work there :cool: . May I ask how your front spoiler works with the arches ? Is the spoiler glass fibre with the arches moulded in ?

CheeRS

Thanks for all the comments. The front spoiler and arches are fiber glass and have been blended in to look like one part.

John

[yellowcustom]

cracking car you have+all work is to mega top standard-congratulations

[John Hall]

After 2 weeks of failed attempts to start the car due to incorrect ECU fuel pump and crank position sensor wiring and a fuel leak.:mad: The car started first time this afternoon:D . It has a few glitches to sort out before I can start the proper mapping, but it was a relief to see the engine running with a rock steady idle only a after a few minutes of starting.:cool: The Lakes here I come :jumpy: ………. after a lot of late nights ahead getting the car finished.

John

[paul spence]

keep at it john

[paul andrews]

great car,very well done jon

[docscars]

top job John looking very well :cool: :cool:

[Mogsmex]

about time nice one, every morning for the past 2 weeks I have been going round to see John to find out if the duratech was making noises :) well done, looking foward to the lakes :cool:

at least you got an engine and gearbox in yours :confused: :p

[oldskooljoe]

keep at it:cool:

[pushrod]

Really, really nice. Hope you get all the gremlins sorted to please. Is this the sort of engine you will always be tweaking or once set up can you just 'leave it alone'?

Nice motor. :)

[Hoogi]

There are a couple of Mk2's being built at the moment that really are at the top end of the quality range and this is one of them..............

I've watched this from the first thread to now and it just gets better and better, so pat yourself on the back...........top work.

Looks like you're on the finishing straight now so guessing Summer should be fun !!!!!!!

Good Luck with the last few bits..............now it looks like all the efforts been worth it eh ? :notworthy: :notworthy: :notworthy: :notworthy: :notworthy: :notworthy:

[John Hall]

Really, really nice. Hope you get all the gremlins sorted to please. Is this the sort of engine you will always be tweaking or once set up can you just 'leave it alone'?

Nice motor. :)

Thanks for all the comments.

The ECU has full emulation and the capability to map “on the fly”, which means I can make changes to the fuel, spark maps etc while the car is being driven with a laptop connected. I will be making tweaks to the spark and fuel maps for a few months to optimise the engine as it runs in. It also has an on board data logger which you can down load all the parameters from the ECU to a laptop for analysis after the ignition is turned off, which is a useful tool when mapping, track days etc.

I had the suspension geometry set up last night by a colleague at work who knows a lot more about setting up a Group 4 set up than me. Now, the car has a good suspension base line set up and will allow me to drive the car to run in the engine and do the part throttle mapping. Once the engine has about 10 hours running, it will then be ready for a rolling road session to do the wide open throttle mapping.

I have taken 2 days of off work to get through the snag list.
Things are going well and it should be ready to start the idle and no load mapping this weekend.

A few pictures of the finished engine bay, just the air cleaner and strut brace to fit.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Bay3.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Bay1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Bay2.jpg

John

[RS2000&MEXICO]

thats some car john...well done:D

[oldskooljoe]

wow....stunning John:cool: :cool:

[marky4]

what an engine bay :cool: :cool:

[Martin]

Awesome work John :bow: wish I had the ability to do this sort of installation

[graham John]

bet you cant wait to get it running correctly, well done, looks great,


cheeRS

[Joe]

I've been watching this thread from the start. What a fantastic job, very different and very impressive.

CheeRS,

Joe.

[rs1800mk2]

You have made a truly outstanding car - and I am truly jealous!

[John Hall]

Quick up date.

Finished all the engine running snag issues and the engine runs with no problems. Just finished the first mapping session and for the first time in about 7 years the car moved under its own power. :D

A few pictures of the completed engine bay.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Finished_Engine_Bay1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Finished_Engine_Bay2.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Finished_Engine_Bay3.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Finished_Engine_Bay4.jpg

John

[oldskooljoe]

A massive well done John:cool:

[vinny]

lovely john, you've done a great job

[y peril melyn]

waw, nice motor
:jumpy:

[andym]

Just amazing .............Great work.... Bet your happy with it..

[stupot]

Stunning Build, excellent.........

[Hoogi]

When can we see a pic of the whole thing ???????

PLEASE :jumpy:

[Mogsmex]

When can we see a pic of the whole thing ???????

PLEASE :jumpy:


there buried in the thread :D

http://i213.photobucket.com/albums/cc23/Hall_Effect/Harrier_6.jpg

stunning it looks too :cool:

[Andyc]

I want one
your car is lush very nice matey
Andyc:)

[Mogsmex]

update required ;)

[hotrs2000]

just read the whole thread from the start (not much going on at work at the mo:D ), John your car is sex on wheels mate:salute: , this has to be one of the best builds in a long time. Get yourself a beer or two:occasion5: :D

[John Hall]

Thanks for the comments.

The car has a few teething problems and I had cancel my Lakes Tour entry a few days before the event.:(
You never know how a car is going to perform until you start driving it.:eek:

Problems I am currently working on:-

Long brake peddle – replace rear master cylinder from 0.7 to 0.75 and front master cylinder from 0.625 to 0.7. I have already done the rear and the peddle feels better, I am replacing the front this weekend.

Handbrake cable running on top of propshaft – raised handbrake lever / mechanism by 12mm to bring cable higher in the prop shaft tunnel.

My ECU supplier said I was getting an ECU with full emulation, but it was not the case. :mad: The ECU could not drive a wide band lambda sensor, which meant I could not measure or adjust the air fuel ratio mixture. So basically, the car drove like a pile of shite and stalled every time the car came to a stop or the engine cooling fans cut in. The ECU supplier went on holiday the weekend of the early May bank holiday and returned last weekend. I am getting the full emulation ECU today.

No engine temperature gauge or fuel level gauge. Both gauges are still dead after replacing regulator on the back of the clocks (Thanks to Miniliteman for supplying me with a NOS one), changing engine coolant temperature sender unit on engine and fuel level sender unit in tank (Thanks to Rob the Hoarder for lending me one), the vehicle loom is refurbished but I still checked it for continuity and it is OK. So the only part of the system not replaced is the actual gauges them selves in the dash, which I do not have any spares. Therefore I need to get both of these gauges that are known to work or a complete orange needle set of clocks. Any one out there got these parts, please PM me.

Once all this has been done. Map the ECU enough for me to be able to drive the car to the MOT station. Then finish the mapping.

Cheers

John

[rwdrs]

the copper circuit is OK on the rear of the clocks is it?

they play up a treat and could well be the earth for the gauges at fault.:confused:

[MerryMart]

Hello John,

I have been reading this thread from the start and it looks if you are nearly there !!

Just a wee question about the ECU/engine mapping. Will it be possible to have 2 different set-ups in the car, what I am struggling to say is, will you have a 2 way switch with like a cruising/conserving fuel mode, and then your enemy pulls up alongside you in his car and you switch to all singing and dancing sport mode and leave him standing ? Or do you need the laptop to change

That would be good methinks, cruise along getting high mpg and then at the touch of a switch, when the notion takes you (little boy racer at the lights), change in to race mode.

Eagerly awaiting your reply,

Martin.

[graham John]

looking forward to hearing more, hope you get it sorted,


cheeRS

[John Hall]

Martin

Yes it is possible to have switchable maps on an ECU. Two examples I can think of are World Rally Car to switch off the anti lag on the road sections and F1 for pit lane speed. My ECU can have this feature but it is very expensive, most people just flash the ECU with the different maps with a laptop. This only takes seconds but can only be done with the ignition on and not with the engine running. Also, for naturally aspirated engines where the maps are optimised for cams, exhaust and intake runner lengths etc, to switch to un-optimised fuel and spark maps would be detuning the engine.

John

Hello John,

I have been reading this thread from the start and it looks if you are nearly there !!

Just a wee question about the ECU/engine mapping. Will it be possible to have 2 different set-ups in the car, what I am struggling to say is, will you have a 2 way switch with like a cruising/conserving fuel mode, and then your enemy pulls up alongside you in his car and you switch to all singing and dancing sport mode and leave him standing ? Or do you need the laptop to change

That would be good methinks, cruise along getting high mpg and then at the touch of a switch, when the notion takes you (little boy racer at the lights), change in to race mode.

Eagerly awaiting your reply,

Martin.

[Mogsmex]

popped over Johns after work today to hear the harrier making noises :wav:

and it's looking and sounding stunning, Johns out in at the mo mapping it ready for the MOT in the morning :)

then assuming all go's to plan it will be debuting at a classic ford show near you soon :D

http://img.photobucket.com/albums/v94/mogsmex/Picture017.jpg

scrummy


http://img.photobucket.com/albums/v94/mogsmex/lvf1.jpg

puffy stuff coming out of the exhaust :cool:

http://img.photobucket.com/albums/v94/mogsmex/lvf2.jpg

I think this is how you adjust the points on it :scratch:

I'm sure John will be along later after the first drive :occasion5:

[paul mex]

"I think this is how you adjust the points on it :scratch:"
Sorry mate Im sure your wrong :confused: Everone knows hes rejetting the carbs:cool:

[marky4]

can't wait to see this car in the flesh:) it's a stunner :cool: :cool:

[John Hall]

Just got in after mapping in torrential ran for 3 hours.:mad: Not the ideal conditions for mapping a car that has never been driven on the road since it was built. We took the first few miles very cautious before I was confident that the car would not fall apart and that all the teething problems were resolved. The mapping of the part throttle fuel and spark is in good shape and the wide open throttle fuelling is set a tad rich with the spark set safe. As the car has only done 40 miles and will need a few more mile on the clock before I can release it full potential. The guy sitting the passenger seat at the lap top is Tim. He is a colleague of mine at FMC Dunton. His job is an ignition mapping specialist for all Duratec engines so I have ended up with an engine map that has good part load drivabilty and is tuned safe at high rpm and wide open throttle. :D

The car is now ready for the drive to the MOT station at 11:30 tomorrow morning. If all goes well, you will see the car and me at the Classic Ford Show on Sunday with Glyn, Rob and Gary. :cool:

Cheers

John

[marky4]

nice one john:) good luck with the mot today ;)

[John Hall]

nice one john:) good luck with the mot today ;)



Cheers, just got home with a MOT pass. :D


John

[paul spence]

nice one john:salute:

[vinny]

Cheers, just got home with a MOT pass. :D


John

great news john

[Hoogi]

Spot-on..............get driving :D

[Mogsmex]

I have been out in the harrier this afternoon with John and suffice to say it's damn good fun and when run in will go like a rocket :D

he's got some ticket in the window as well today even paying for a whole wasted month just to make santa's pods

good effort :cool:

I expect he'll be buftying now

really looking foward to Sunday

[marky4]

glad it passed ;) :)

[paul andrews]

well done jon,very nice car m8:)

[John Hall]

Escort is taxed.
Cleaned, polished, fuelled up and ready for the 6am start from Glyns house.
Who ever is going, see you there. :thumbright:

John

[Miniliteman]

Good to see you the car is ready John, have a good trip.

Leon.

[John Hall]

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/RAC_Tow.jpg
Those of you that do not know the car broke down with a suspect rear gearbox oil seal failure about 25 miles from Santa Pod on the day of the Classic Ford Show.:(

See Robs "missing in action" thread for more info….

http://bbs.rallyesportescorts.co.uk/showthread.php?t=27595

When I tried to remove the propshaft from the rear of the gearbox, it became more apparent that it was more than an oil seal failure. It took about an hour with a club hammer to get the prop to come off of the spline. This is what it looks like. :eek:

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Damaged_Prop.jpg

This is the result of the white metal bearing over heating, seizing and then spinning in the tail housing. I bought the gearbox that needed reconditioning from a guy that had it in a 500 bhp Serria RS500 Cosworth running on slicks, that he used for 0 to 60 launching competitions etc. The gearbox was reconditioned before I built up the car, but they never replace the white metal bearing because it never fails.:confused:

After the gearbox was repaired with another tailhousing with a checked bearing and new rear seal. The installation angle (white metal bearing is oil gravity feed), propshaft length, running clearances and run out were checked and found to be OK.

The only conclusion for the failure is the stress that the gearbox was under when it was being used for 0 to 60 launching competitions and the tail section / bearing was out of alignment.

The car is now running and I drove it to the Ford Dunton Employee Vehicle Enthuisasts Day yesterday, which is about 10 miles with no problems. I now need to drive it for a longer run as it failed after about an hours motorway driving.

John

[mike77cos]

Fingers crossed all will be ok mate

[pushrod]

What a real let down. Hope the universal on the prop hasn't got overheated!

Lovely motor.

All this mapping and emulation is just clean over my head.
WTF is emulation?
What sort of horse power are you predicting/hoping for?

[Mogsmex]

just to unearth this thread from the back pages :D

John's car is now all up and running :cool: and going very well indeed :eek:

it was the subject of an article for Retro Ford on saturday with the pics taken at Ford's Dunton test track where me and John work, I took a couple of pics of the day that I thought I would post on here for you lot as a little teaser before the mag comes out, I have seen some of the originals that Simon the photographer took and they look the doggy's doo daa's :D

http://img.photobucket.com/albums/v94/mogsmex/DSCF0363.jpg

sheltering under the essex group gazebo getting it's hair and make up done before the shoot


http://img.photobucket.com/albums/v94/mogsmex/DSCF0375.jpg

the banking :spliff:

http://img.photobucket.com/albums/v94/mogsmex/DSCF0380.jpg

John being photographers mate :cool:


looking foward to seeing the mag :D

[John Hall]

Firstly. A big thanks for Glyn helping me on the photo shoot, which involved a lot of car pushing and not much driving.:thumbright:

Here is the link to the photographer Simon's web site with some of the pictures he took on the Dunton test track.

http://picasaweb.google.com/Evosico/WHITEESCORT061020081319?pli=1#

A colleague at work said I should get the car featured in a magazine, but after getting the car running and then the gearbox / propshaft failure and then missing every car show this year due to a never ending list of gremlins. I entered the car in the employee vehicle enthusiast's day, drove the car home threw a dust sheet over it and did not go near it for two months.:mad:

It was Simon contacting me about doing a magazine article after he saw my car posted on the Passion Ford web site about the employee vehicle enthusiast's day that got me fired up about the car again.:D

First on the agenda was some wide open throttle / high load mapping as the engine done enough running for this to be possible. With the fuelling and spark maps now tuned, the engine is starting show it full potential. So good that the clutch started to slip at wide open throttle in forth and fifth gear. :eek: The mapping session was stopped at this point as the maps were good enough for the photo shoot. The clutch will have to be up rated before the mapping could be completed, most probably a rolling road session.

Now I have a long list of jobs that need doing to the car and six months to get them all done before the 2009 show season starts.

John

[Mark M]

great read, great car. well done........:thumbright:

[Hoogi]

Fantastic read............what a car :D

[havard01]

A sexy looking car

[npikey]

Just read this thread and what a job ! looks the muts nuts m8 :cool:

[Mr Hoarder]

http://img.photobucket.com/albums/v94/mogsmex/DSCF0363.jpg



Do I spy my now much depleted can of Autoglym radiant wax polish in that photo :rolleyes:

[Mogsmex]

Do I spy my now much depleted can of Autoglym radiant wax polish in that photo :rolleyes:


nah that cant be yours as yours was full and that ones empty :p

[dick_dastardly]

fantastic car

[Lord Lucan]

fantastic love the engine looks like it belongs in there

[AQUA]

Marvellous and genius.

I have to see this car in the flesh next year, must get some leave and get to a show in 09.

[John Hall]

Thanks for all the comments.
I had the telephone interview with Simon the journalist / photographer about the car for the Retro Ford article on Tuesday night.
Lots of plugs about the Rallye Sport Escorts BB.
Should be published in the new year.

Cheers :thumbright:

John

[5hane]

hey :)


just read the thread start to finish :cool: very nice :D

looks tonnes better in real life too! :cool:



cant wait for the feature too :)

[John Hall]

Shane

Good to meet you and your dad today.:thumbright:
Small world eh.
Gald you like the car.:D

Cheers

John

[5hane]

Shane

Good to meet you and your dad today.:thumbright:
Small world eh.
Gald you like the car.:D

Cheers

John


very small world lol !

next time you will have to look around our colection.. not as clean tho :o

[marky4]

what a stunning car :cool: :cool:

[jonnie205]

looks lovely, is that puma one of the puma road cars from borehema when that shut, are the transit service vansa dn all workshop kit still at dunton from when they cleared out boreham?

[John Hall]

looks lovely, is that puma one of the puma road cars from borehema when that shut, are the transit service vansa dn all workshop kit still at dunton from when they cleared out boreham?

Thanks for the comments.
Yes, the Racing Puma belongs to Glyn (Mogsmex) and is one of the 500 Tickford production run. As far as I know, every thing to do with Boreham was sold off in auction lots. There was some service vehicles at Dunton for a while after Boreham closed to support the Super 1600 Fiesta's. But they have now gone.

John

[jonnie205]

oh i see, it would interesting to know wher ethe service vans went, i delivered to back there which we had on loan and they were spot on vans, all kitted out etc

[John Hall]

:thumbright:Thanks to Dave (RS2000CUSTOM) for giving me editing rights to this post. As I had lost all the pictures on the first 10 pages of this thread. I have now linked the 116 :eek: missing pictures that were on the Red Slate server to the same pictures now on Photo Bucket.

A list of the winter jobs to be done before I can map wide open throttle on the rolling road.

Oil Leaks

The sump is fabricated and has oil leaks from porous welds where the fabricated part of the sump is welded to the original cast part of the sump, which bolts to the block. I should of pressure tested the sump after the engine was built up, but I forgot to do it. With help from Glyn (Mogmex), we have taken the engine out of the car and pressure tested the sump and found four porous welds. One of which was hidden under the cross member when fitted in the car was a large leak.

Slipping Clutch

Fit an uprated clutch as the one supplied by Raceline is only rated to 200Nm of torque. Even though 200Nm is the maximum torque the engine should produce. The clutch supplied was for a kit car / Caterham application and the weight difference between a kit car and an Mk2 Escort has caused the clutch to slip when the engine hits the powerband or dumping the clutch from a standing start.

Fuel Surge

When the petrol tank gets below a quarter of a tank the engine looses power when going around roundabouts or take a sharp left. I always knew the fuel tank was not an EFI version and had no well in the bottom to stop fuel surge. To stop the surge I had always made provision for a fuel swirl pot and scavenge pump set up if I had problems with fuel surge.

Sorry no pictures my camera has packed up and gone back to Canon for repairs:mad:.

John

[John Hall]

I have been meaning to up date this thread for ages, so here goes.

The sump was pressure tested, porous welds found, removed from engine, welded, fitted back to engine, pressure tested, still leaked:mad:. Welded again, this time with sump still fitted to engine and pressured tested at the welders and did not leave the welders until the sump was leak free.

Engine refitted into the car with new 250 Nm AP clutch fitted.

Fuel swirl pot and scavenge pump fitted and plumbed in to boot to stop fuel surge at low fuel levels when cornering.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/SwirlPot2.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/SwirlPot1.jpg

Propshaft was very out of balance, sent it to Reco Prop in Luton. Who re-tubed the propshaft and dynamically balanced it up to 9000 rpm.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/RecoPropshaft.jpg

Shows attended in 2009.

Lakes Tour 2009 - Won “Car of the Tour”

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/LakesBestCar2009.jpg

Classic Ford
AVO national day
Battlesbridge All Ford Classic car show

Good to meet very body who had commented on the build up of the car on this BB and for them to see the car in the flesh.

Job list for 2010 season (Now all done ....I will cover in another post)

New AP front brakes from R.A.C.E
New Gartrac Bias pedal box
New Gartrac group 4 throttle pedal
Flocked dash top and clocks binnacle

See you all at the Lakes in May

John

[Dave1800BDA]

lovely car John, a credit to you

the sump saga seemed a bit of a nightmare

[John Hall]

Driving home from one of the shows last year, I had a bit of a moment were the car just did not stop as I expected it to. Luckily, it was late at night and the mini roundabout I went straight over whilst trying to push the brake pedal through the floor was free of traffic.:eek:

After some internet research on the much discussed subject of Mk2 Escort Bias Pedal boxes, what size master cylinders to use and what make of calliper and pads to fit. It became clear that the combination of :- specification, quality and reliability of my front braking set up was not capable of stopping a 1 Tonne 250 bhp Escort every time I pushed the brake pedal with out fail.

Gartrac Bias Pedal Box with hydraulic clutch

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/GartracPedalBox1.jpg

The most expensive bias pedal box there is, but this is why. The pedal box comes fully assembled by Gartrac. With your specified master cylinder rods cut to the correct length for free play when the brake pedal is up. The bias bar is installed and clevises are set to the correct clearance with the bias tube.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/GartracPedalBox2.jpg

The front master cylinder is fitted in the centre position of the hydraulic clutch version of the pedal box, not to the right hand side of the pedal box as fitted in most pedal box set ups I have seen. The only reason I can think why Gartrac fit the front master cylinder in centre position. Is that this is the most mechanically efficient position, so that when the brake pedal is pushed more of the force applied gets to the front master cylinder than the rear master cylinder.

But the primary reason why I went for Gartrac is that the pedal box has built in bias to the front brakes. This means that when the bias bar is horizontal there is about 30% bias to the front brakes before the need to dial in any bias for the front master cylinder and taking the bias bar off of its optimum setting of horizontal.

Pedal box fitted to car with Gartrac Group 4 throttle pedal which will be the subject of another post.


http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/GartracPedalBox3.jpg

Front Brakes

Only one choice of make …..AP. I had read Graham John’s “The Black Beauty” build thread and liked the Rally And Competition Equipment (R.A.C.E) AP front brake kit he had fitted. I spoke to few others who have the same kit fitted and did not say a bad thing about it. So the choice was made.

What a well designed brake kit. It is all in the design of the mounting bracket; it must have been designed using CAD.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/APBracket1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/APBracket2.jpg

With the calliper fitted to the bracket, the calliper sits on the centre line of the front disk.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/RACEAPBrakeKit1.jpg

The callipers are so big that they just fit over a 13 inch rim, with just millimetres of clearance. The first time a put a wheel over the brakes, the wheel would not do a full revolution due to the calliper hitting the stick on wheel balance weights on the inside of the rim. I had to remove the weights to get the wheel to spin freely. Then get the wheels re-balanced with the weights fitted out of the path of the calliper.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/RACEAPBrakeKit2.jpg

The performance of the front brake set up of Gatrac pedal box, AP front callipers with 0.625” master cylinder and Mintex 1144 pads is phenomenal. With less than a 100 miles of bedding in, they are pulling the car to a stop like no other un-servo’d car I have ever driven.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/RACEAPBrakeKit3.jpg

The only niggle had was brake squeal on light braking. When I was bedding in the brakes, I drove the car over to Robs at Hoarder Towers and he gave me a sachet of “Blue Goo”. Which I coated the back of the brake pads with applied the brakes and let cure for 24 hours and now… no brake squeal.

Nice one Rob and thanks for fixing a punctured rear tyre while I was visiting…what a service.

John

[para144]

I use the same brakes on my rally car with DS3000 pads...great brakes but they do squeal!

[Mr Hoarder]

The only niggle had was brake squeal on light braking. When I was bedding in the brakes, I drove the car over to Robs at Hoarder Towers and he gave me a sachet of “Blue Goo”. Which I coated the back of the brake pads with applied the brakes and let cure for 24 hours and now… no brake squeal.

Nice one Rob and thanks for fixing a punctured rear tyre while I was visiting…what a service.

John

You are welcome John :)

[taffr]

that gartrac pedal box set up looks awsome john, apparently GJ says he has no prob's with squealing brakes:rolleyes:

[Miniliteman]

that gartrac pedal box set up looks awsome john, apparently GJ says he has no prob's with squealing brakes:rolleyes:

No squeal? What's his secret??? Giraffe oil? :rolleyes:

[paul andrews]

nice car and nice set up jon,ive got aps on my mk1 and mk2 and the brakes are awesome with again no brake noise at all,unlike my bloody old wilwoods.top motor this

[Mogsmex]

any updates ?? thought I heard a grinder :rolleyes:

[Hoogi]

Have the same set-up on mine but for 15" wheels - unfortunately I bought them about 3 years ago and the car still hasn't turned a wheel.

So, mine don't make a noise either :sulkoff:

[Mr Hoarder]

any updates ?? thought I heard a grinder :rolleyes:

You heard an air saw not a grinder :D

http://i227.photobucket.com/albums/dd267/Mr_Hoarder/e5c47c4c.jpg

[John Hall]

any updates ?? thought I heard a grinder :rolleyes:

The sound of the grinder from Hoarder towers will be the subject of a new post.
Over to you Rob.

[Mr Hoarder]

The sound of the grinder from Hoarder towers will be the subject of a new post.
Over to you Rob.

I'll cover the whole story in one post when it's done I think :D

I'm sure the debate on "Max Power" style aluminium chequer plate exhaust heat shields will rage on while I'm cutting out the small semi circle from the new back panel :D:D

[John Hall]

Have the same set-up on mine but for 15" wheels - unfortunately I bought them about 3 years ago and the car still hasn't turned a wheel.

So, mine don't make a noise either :sulkoff:

Hoogi

Escort been on the road for 2 years, with 2 very enjoyable Lakes Tours completed. Fitted the AP front brakes with Gartrac Pedal box last winter .....the car now stops as well as it goes..:D

[John Hall]

I'm sure the debate on "Max Power" style aluminium chequer plate exhaust heat shields will rage on while I'm cutting out the small semi circle from the new back panel :D:D

Decisions….. decisions, I think I will lose some sleep on this one :rolleyes:

[Mr Hoarder]

The sound of the grinder from Hoarder towers will be the subject of a new post.
Over to you Rob.

New thread here :

http://bbs.rallyesportescorts.co.uk/showthread.php?t=50140

[John Hall]

At last the Escort is back together and ready for the Lakes Tour 2011. :D
I started to refit out the boot back in January, but I went on a business trip with work and did not get the car fully assembled until mid March.

I waited until the 1st of April to tax the car and then took the Escort out for a road test to check that the refit to the fuel system had not changed how the car performed.

I had connected the lap to the ECU to data log the test drive. The results showed the fuel pressure was fluctuating by about a bar, this was making the fuelling go lean randomly. This was not good as I could in a worst case scenario damage the engine. :(

Also, while the engine was idling, I could hear the running sound of high pressure fuel pump changing note. I had plenty of fuel in the tank, so it had to be an electrical fault.

Few checks with the volt meter showed I had good voltage at the pump, but when I checked for continuity on the earth…..it was poor.

The cause, fresh paint over the pump earths to the chassis ground. :o A clean off of the paint at the chassis earth and an additional earth wire from the low pressure pump to chassis ground and the fuel pressure was back at a steady 4 bar. :D

Pictures below of refit.

Escort delivered back from Hoarders Escort Emporium in early January

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/New_Rear_Panel_1.jpg

Wiring Loom and battery cable laid out

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/New_Rear_Panel_2.jpg

Battery and wiring

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/New_Rear_Panel_4.jpg

Fuel tank

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/New_Rear_Panel_5.jpg

Fuel pumps, filter and swirl pot

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/New_Rear_Panel_6.jpg

Spare wheel post and spare wheel

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/New_Rear_Panel_7.jpg

Finished with rear lights, rear bumper and badges

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/New_Rear_Panel_8.jpg

Before and after shots.
First with the old back panel with cut out, this is the only picture I have of the rear of the car which has taken an age to find. :mad:
This was taken on the high speed banking on the Ford test track at Dunton for the Retro Ford Magazine article.
Strange that all the hundreds of photo’s that I have taken, I never have taken a photo of the back of car. I must sub consciously never liked how the car looked from the back. :eek:

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/New_Rear_Panel_9.jpg

Job done

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/New_Rear_Panel_11.jpg

John

[alancdavis]

Looks good,,,,

[Dave1800BDA]

very nice John, good work there:cool:

[Andyc]

very very nice

[Mexicomark]

First with the old back panel with cut out, this is the only picture I have of the rear of the car which has taken an age to find. :mad:
This was taken on the high speed banking on the Ford test track at Dunton for the Retro Ford Magazine article.
Strange that all the hundreds of photo’s that I have taken, I never have taken a photo of the back of car. I must sub consciously never liked how the car looked from the back. :eek:



John

One on the way back from the lakes last year

http://img705.imageshack.us/img705/5697/dsc0166vl.jpg

[John Hall]

One on the way back from the lakes last year



Cheers for the pic Mark :thumbright: I have never seen a photo of the Escort taken from behind on the road. For me, this photo confirms that I have made the right choice to replace the rear panel.

John

[Martin]

Very nice John, and better with the back panel replaced :thumbright:

[Dazzle]

Looks really good John :thumbright:

Nice one :D

[Mr Hoarder]

The cause, fresh paint over the pump earths to the chassis ground. :o A clean off of the paint at the chassis earth and an additional earth wire from the low pressure pump to chassis ground and the fuel pressure was back at a steady 4 bar. :D


Whoops, that will be all that paint I put on ;)