Mk2 2.3 Duratec

[John Hall]

Hi

First some pics of the car

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Mk2_Pic8-1.jpg

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

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Mk2_Pic6-1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Mk2_Pic1-1.jpg

And now the engine installation

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Mk2_1-1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Mk2_3-1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Mk2_4-1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Mk2_5-1.jpg

I hope you like :thumbright:

JOHN

[Banishit]

what a stunner, absolutly beautiful

I see the 2.3 badge for the rear end, do you know you can get a proper 2.3 one of those from a Granada ?

cheers
Brian

[Robb]

Loverly looks like its ment to be there :thumbright:

[John Hall]

Brain

No, I did not know about the Granada 2.3 boot badge. Does it come in black and do you know the part or FINS number ?
I made the boot and the wing badges from Escort 1.3 and 2.0 badges.

Thanks for you comments

John

[james cruise]

Absolutly beautiful John, Are they direct to head jenevy t-bodies

[wiggyrs]

Hi John, your car looks stunning :thumbright:

[John Hall]

James

Yep. Throttle bodies are direct to head Jenvey's, but have Raceline stickers on them, Jenvey is cast into the underside of them. It has to be those because if I used an adaptor manifold, I would not have much space for air filter / air box in the space between the throttle body and the inner wing.

The exhaust manifold is a work of art, it was made by Tony Taw. To the Mountune Duratec specification used for the Grp 4 Mk2s in the Irish Mk2 Rally Championship.

Thanks for the comments.

John

[ian parker]

that looks really really smart !!

[RS2000CUSTOM]

:cheers: Again this BB attracts another stunning MKII :cheers:

Nice work John

[Frosticles]

VERY nice looking car you have there :cheers: Like to see it when it's finished.

[RabC-RS2-77]

diamond white always' alwhyte..... nice car.

[Mark M]

very nice car indeed, and nice looking engine install.
p.s. the 2.3 badge is available from burtons @ £9 + vat.

[ders]

Hi John,
you car looks superb :thumbright: ...is it going on the track this year?

cheeRS Ders.

[vinny]

looking good john

[Andrew T]

Bloody Hell!...........very nice!!
Welcome to the site John.

[Deepest Blue]

http://img52.imageshack.us/img52/3592/dogsbollocks5ic.jpg (http://imageshack.us)

:cat:

[paul spence]

very nice john, :salute:

[Nelly]

Stunning, absolutely stunning!! Love the arches & front spoiler. :salute:

[lar]

Hi there. Thats a very very nice car. Good luck with getting it sorted.

[lee bishop]

VERY nice looking car you have there :cheers: Like to see it when it's finished.

oh yeah kev, well i like to drive it when its finished......LOL

[John Hall]

Hi

Thanks for the comments.

Plans are to have the car finished for July as I want to show it at the Ford Motor Company Employee car show at Dunton. But have some problems to sort first. The major one is the company that was making me a new wiring loom has disapeared of of the face of the earth and I need to find some one else pritty dam quick or this will stop the final assembly. The engine in the photo's is a dummy engine (just a bare head and block), my engine is being built this month. After that the cossie T5 gearbox need to be rebuilt with a new ratio gear kit for N/A engines.

After that its plan sailing :thumbright:

John

[pushrod]

Really nice. Looks like a lot of time has been put into it already. You must be well pleased.

[RabC-RS2-77]

well hopefully you get over those rougth seas pretty soon, to that plain sailing, lol.

[graceloc]

wow lovley motor, super looking paint job too.....Gerard.

[martin c]

Stunning M8 :thumbright: :thumbright: :thumbright:

[RabC-RS2-77]

http://img52.imageshack.us/img52/3592/dogsbollocks5ic.jpg (http://imageshack.us)

:cat: ****ing hell neil that must have took allnight for you 2 cum up wi that
picture lark,lol.

[RTo]

Nice!
Do you have pics with the engine out showing the mounts etc?

My mk2 is getting some Duratec treatment too. Only 2.0 though.
After looking at the Raceline brochure I think I'll be getting the engine from them.

[Aaron P.]

john

thats a very tasty looking mk2....have you got a spec on the engine yet? did u get ur exhaust manifold custom made?? im doing a bit of checking out for doing this job myself in my mk2 van.....all depends on my budget at the end of the day....

[harrier mark 2]

what a cracker ! credit to you mate, lovley car.

[John Hall]

Aaron P.

The specification of my engine is the Raceline 250 Spec. Torque and power numbers for this spec is 200 pound / foot at 5000 rpm and 250 bhp at 6000rpm with maximum rpm at 7000. Engine spec as follows

Crankshaft – standard lightened and balanced with Raceline light flywheel.
Conrods - standard balanced statically and dynamically with ARP bigend bolts.
Bearings – Heavy duty Vandervelle VP3 for all journals.
Pistons – Raceline Omega high compression, takes compression ratio from 9.8:1 to 10.8:1.
Head – New Ford “high Flow” head with standard valves.
Cams – Raceline RLD220 camshafts with heavy duty valve springs and vernier timing pulleys.
Intake – Jenvey direct to head throttle bodies with Pico 330mm injectors and K&N filters
Exhaust – Tony Law 4-2-1 exhaust manifold, optimized to Mountunes specification.
ECU – Pectel T2 with spark and fueling maps supplied by Mountune and optimized by myself on Dyno and Rolling Road.

I will find some pitures of engine mounts and sump and post them latter.

John

[Aaron P.]

that engine makes the car as not many of these have been yet.....it looks like a typical arched escort but then pop the bonnet & droll .........its defo an awsome motor & inspiring to alot of us doing resto's......keep the pics coming..... :cheers: :cheers:

[John Hall]

Hi

I have had a few PM's on how the engine was installed, so here goes....

To get a 2.3 Duratec and Cosworth T5 gearbox into the Mk2 took a lot of work and I sent the car to a company that specialised in custom engine installations.

I found and imported from a company in the USA, that have cast a bell housing to fit the cossie T5 to a Duratec.

The work that was done to the car and engine are as follows.

Fabricated wet sump to allow the engine to sit as low as posible with a world cup cross member and std rack.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/IMG_0774.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/IMG_0775.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/IMG_0275.jpg

Fabricate engine mounts to mount the engine to the word cup cross member.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/IMG_0277.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/IMG_0281.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/IMG_0282.jpg

Modifications to the bulkhead to allow the engine to sit back in the engine bay as far as posible and clearence for the water rail and to allow the oil filter housing to clear the world cup cross member and engine mount. The oil filter housing is still very tight and I have decided to to with a remote oil filter option.

Fabricate a rear gearbox mount and modifations to the gearbox tunnel to fit the mount to the body.

John

[james cruise]

Thats very neat John and how thin is that sump "crazy". Its
good to see a different engine conversion other than all these
cossie and zetec jobbies. Noting wrong with them of course.
Keep it up mate :thumbright:

[Banishit]

thats some nice work, what does that sump hold? or are you having a resovior aswell

Cheers
Brian

[John Hall]

Hi

Sump holds 3.5 litres were as standard 2.3 Ranger sump holds 4.0 litres. The difference will be made up in the remote oil filter / cooler and pipe work. Aslo like all modern engines the Duratec has a deep skirt block, which means the crankshaft is alot higher in the block when compared to Zetecs, Pinto's etc. This enables the oil to be over filled by up to 1 litre before crank splash and oil foaming occours.

John

[RTo]

:notworthy:
Thanks for the pics.
I have one more request - can you take a pic of the sump when the engine is in place? Basically I'd like to see the clearance.

[John Hall]

RTo

Sorry I have been digging through all my installation pictures and can not find the picture you asked for.
I would take some more pictures but the engine is not in the car right now.

Regards

John

[Aaron P.]

john

ive been doing some checking on these engines & a company i rang last week told me they can do the 2.3lt cheaper than the 2lt.....2.3lt on throttle bodies brand new engine etc roughly 220bhp for £3800.....not sure if thats a good price but it seems to be the cheapest out there for a new one.....how much did it cost for the manifold to be done??? (if ya dont mind me asking)......keep your pics coming :thumbright:

[John Hall]

Aaron

£3800 sounds good money.
Whats the spec of the engine, pistons, cams, head work, bottom end etc.
Does it come with a sump to fit in a Mk2 ?
My exhaust manifold cost £500 and was made by Tony Law who is based in Leeds.

Have you been posting questions on Turbosport ?
Because I think I have replyed to a question you asked in the Duratec section.
I am RWD_COS on Turbosport because I also have a rear wheel drive Escort Cosworth, but thats another story. :thumbright:

John

[Aaron P.]

john

that price was from scholar engines, but as far as i remember thats for a standard engine & yes it comes with a dry sump....the oil tank has to be bought seperately.
the manifold sounds rather expensive but i know nothing of the cost of them
yes im a regular on TS as well & was chuffed to see ur car appearing here on this forum. not many conversions done yet so the info is good for me.......keep the pics coming :cheers:

[garthbtp]

Very nice installation.

Cheers Garth

[vinny]

any movement latley john ?

[John Hall]

Not much happening at the moment.

Waiting for the engine to come back from the engine builder.

Finished the installation of rear axle.
I will take some photo's of it and post them, if any ones interested :D .

Rob aka Mr Hoarder came and had a look at the car last month and gave me a genuine 2.3 black boot badge off of a Mk4 Contina 2.3 S to replace my home made one, cheers Rob :thumbright: .

I am still looking for some one to make a new vehicle loom, if any one knows of any one, PM me.

John

[RS2000&MEXICO]

keep pics coming m8....i am very intrested....:D cheeRS

[james cruise]

Did you try any of the rally car prep firms John for a loom. It might
be worth given clint a shout on T-sport cause I know he is gettin engine
looms made for cossie engines so maybe he could point you in the right direction. And keep the pics coming ;)

[John Hall]

Some pictures I took of the axle at the weekend.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Axle1044.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Axle1046.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Axle1048.jpg

Cheers

John

[Banishit]

nice a no nonsense set up

[Robb]

Is that a fostek diff plate i spot there? looks very nice:thumbright:

[Frosticles]

Very nice John:)

[james cruise]

Very nice John, Looks like its well thought out.

[RabC-RS2-77]

looks like its guin to be proper tool...:thumbright:

[Mr Hoarder]

Rob aka Mr Hoarder came and had a look at the car last month and gave me a genuine 2.3 black boot badge off of a Mk4 Contina 2.3 S to replace my home made one, cheers Rob :thumbright: .

You are welcome John, as I said it all goes to the cause :thumbright:

[rs1800mk2]

Do you need a whole car loom or just an engine loom ? I have made a few for Mk2's mostly rally cars.

[John Hall]

Hi

I need a whole car loom.
PM me if you can help.

Cheers

John

[John Hall]

Quick update on engine build.
I had to stop build due to missunderstanding between me, engine builder and the consultant who spec'd the engine for me:2gunsfiring_v1: .

The result of this was I had to buy a set of these.
Which turn up on Friday.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/ConRod1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/ConRod2.jpg

A set of Eagle steel shotpeen'd conrods and come with ARP bolts as standard.
I bought them from the USA for $400 which is £225, cost me about £300 after post, import tax etc. Which is about half of what they cost to buy in the UK.

Just now waiting for a set of ladder frame (bigend cap) bolts and the engine can be assembled.:D

[mkIIvan]

Any more news on your engine John?
Have you sorted every thing out with biuld?

[John Hall]

Had another short delay with the build.
I could not get new ladder frame bolts from Ford.
No standard Ford OEM parts for the Duratec bottom end are vailable from Ford Dealer Spares yet :mad:
I tried to get a set sent directly to me from the engine plant in Mexico, but was taking too long and my engine builder wanted to get on with the build.
So have had to buy a ARP Stud kit for the ladder frame.
The engine is now being built up, head is finished.
Hopefully, it will be fully assembled next week some time.
But we have got to sort out the dipstick tube location and calibrate the dipstick for the fabricated sump before the engine is returned to me.

[Aaron P.]

john its good to hear the bild is still going strong, would love to see the car in the flesh when its done and hear the purrrrrrrrr from it :D

[John Hall]

Engine builders gone on holiday.
Engine will not be ready till the end of the month.
I have asked him to take some pictures as he is building the engine.
I will post them as soon as I get them.

[John Hall]

Well.... after engine builder going on holiday and other commitments, he has started the build. :D

A few pictures as promised.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/PistonCrown.jpg
Piston Crown with Valve pockets

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/PistonOnRod1.jpg
Piston Assembled on Rod

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/ARPStud.jpg
ARP Bigend Stud Kit in Block

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/LadderFrame.jpgCrank and Ladder Frame loose assembled in block.

The build should progress more this weekend and I will post more pictures when the engine builder mails them to me.

John

[mkIIvan]

COOL !

Can't wait now John, nor you I bet? lol

[John Hall]

A few more pictures from the engine builder

Pistons ready to go into block.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/PistonOnRod2.jpg

First piston into block
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/ShortBlock1.jpg

A picture showing the piston clearing the top of the block
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/ShortBlock2.jpg

More to come next week.

John

[John Hall]

A few more pics after the head went on.

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

Cams going in for shimming of the lifters

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

Verniers (with sweat of off hands making them rust :argue: it was a very hot day) and engine builders top secret pencil.

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

Front of engine.

John

[RS2000CUSTOM]

........... and engine builders top secret pencil.



Just a guess but does builder mark each lobe with lead from the pencil and then rotate cam to see where clearance "ends" and cam comes into contact with the tappet bucket ?

Or does he simply write down the clearances as he measures em ! - lol

[John Hall]

Just a guess but does builder mark each lobe with lead from the pencil and then rotate cam to see where clearance "ends" and cam comes into contact with the tappet bucket ?

Or does he simply write down the clearances as he measures em ! - lol

Dave

Your guess is as good as mine.
I thought I would mention the pencil, before someone else did. :rolleyes:
Other suggestions welcome.

[John Hall]

Went to the engine builders to drop off some parts, took some pics while I was there.

Test fit of timing and oil pump chains.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/TimingChain.jpg

Side view of engine
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/EngineInLetSide.jpg

Rear view of engine
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/EngineRear.jpg

John

[John Hall]

The engine is built.
A few pictures of it on my engine stand.

Front View
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Front_View.jpg

Exhaust Side
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Exhaust_Side.jpg

Rear View
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Rear_View.jpg

Intake Side
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Intake_Side.jpg

John

[RS2000CUSTOM]

Have u dyno'ed it or r u gonna run it in fitted to car ?

[John Hall]

Dave

I have the 100 RON MBT spark map for this engines compression ratio and cam profile. So I will most probably fit the engine to the car. Tune the drivability and closed loop fueling on the road, and optimise the wide open throttle spark and fuel with a rolling road session.

John

[Banishit]

very nice

[graham John]

yeah, nice, look forward to the start up

cheeRS

[Miniliteman]

A few more pics after the head went on.

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

John

Never seen cams so peaky ....

[John Hall]

Miniliteman

Never seen cams so peaky ....

Well spotted.
These are not my cams, but cams with nominal base circle diameter used to calculate the valve bucket clearances.

Cheers

John

P.s I have just checked the engine to make sure the engine builder did not leave them in. :eek:

[John Hall]

A few more pics.

I done a trail fit of all the parts that bolt on to the engine at the weekend.
Because all the previous engine installation work was done with a dummy (scrap) block and head.

Exhaust Side view
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Exhaust.jpg

Intake Side View
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/ThrottleBody.jpg

Front View
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/FEAD.jpg

My first mistake is that the alternator belt is touching the front cover :mad: (near the bolt in the center of the cover). I will have to change the 2.3 Ranger rear wheel drive one for a Mk1 2.3 Focus (North America) front wheel drive version. But before I can fit it I will have to get the engine mount bracket machined off.

View From Top Exhaust Side
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Camcover1.jpg

View From Top Intake Side
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Camcover2.jpg

John

[Miniliteman]

John,

why is there a lambdasensor in the exhaust of cylinder no4 ?

Leon.

[John Hall]

Leon

It is a wideband UEGO sensor for mapping, the Lambda sensor tapping is in the downpipe it can be seen in the Intake Side View just past the bellhousing.
There are also thermocouple tappings in primary runner 1 and in the downpipe near the UEGO tapping, these are used for mapping as well.

John

[paul andrews]

anymore progress on this john?did you get the loom sorted out as well m8.clint made mine up for the engine if that helps:)

[roy8v]

just read this post from start to finish and am lovin this car john.any more progress/pics.cant wait to see it when its finished.

[John Hall]

Hi

Sorry for no updates.
I have been very busy with work for the last 4 months.
As some of you may know I work for Ford at Dunton.
Were I am working on a project which goes into production next year.
The final phase of engine calibration development is in teritory testing using a pre-production version of the finished car. I spent a month in southern Italy doing high speed testing at a test track called Nardo. Nardo is owned by the Fiat group and all the big european car manufactures have a test garage there. Nardo is a high speed bowl with one lap being just under 10 miles, the fast lane is speed unlimited. This is the track Ford used to record the Ford GT's max speed of just over 220 mph (I think). Bugatti hold the current track top speed with the Veyron. While I was there Lamborghini were there testing the new Murcielago LP640. Which when comes passed you at V max, when you are in a 1600cc Ford with a top speed of 120 mph is something I will never forget. I am now preparing to go to Lapland in January to do -30°C cold start testing on the same project for two weeks.

Any way back to the Mk2 as I think you can guess, not much has happened.
It took a few months to find a 2.3 front-wheel drive front cover as they are not in any European Ford products (well not to 2007).
I finally found that Cosworth sell them, but not Cosworth in the UK but in Califorina USA. Also, I bought a high capacity oil pump at the same time.
The new oil pump and front cover have been fitted to the engine and the alternator belt now clears the cover.
I found an auto electrician to build me a complete vehicle loom for the car. After meeting him, he tells me he is ex-Boreham autoelectrian and left there in 1998 when Ford closed the motorsport operation down. He never worked on Mk2's but was there from RS200 untill the end with the Super 1600 Puma. But he has made many Mk2 looms since and has two on the go now. He can not start mine untill Feb 07 and will come to my workshop and build the loom on the car.

So when I get back from Finland. Will need to get cracking. I need to get the engine back in the car ready for the loom job. Also, I have just been told that Dunton is 40 next year and the will be a Family Open Day with a Ford Heritage and employee car show. Which I am sad to say there are no Mk2's owned by Ford so mines got to be running for the summer as I am the only employee with a Mk2.

Belated Happy Christmas and a Happy New Year

John

[docscars]

:D great car some time and sweat lost there umust be proud of it:cool: :cool:

[grum]

great update there

sounds like your more than busy

wrap up warm in Lapland -30 :dropmouth:

[ELLISPORT DEVELOPMENTS]

HELLO ARE YOU POSITIVE THAT IS A 2.3 BECAUSE THE 2.3 DOES NOT HAVE A MOUNT BRACKET ON THE FRONT WITH THE 2 BOLTS ON THE FRONT COVER.IT HAS A BIG PULLEY UNLESS YOU ARE RUNNING A ELETRIC PUMP AND THEY HAVE CHANGED THE FRONT COVER.
LOVLEY CAR BY THEY WAY NOT COMITING ON ANY THING JUST HPE ITS RIGHT WOULD NOT LIKE TO SEE YOU HAVE THE WRONG ENGINE INSTALTION.:confused: :confused:

[Mr Hoarder]

HELLO ARE YOU POSITIVE THAT IS A 2.3 BECAUSE THE 2.3 DOES NOT HAVE A MOUNT BRACKET ON THE FRONT WITH THE 2 BOLTS ON THE FRONT COVER.IT HAS A BIG PULLEY UNLESS YOU ARE RUNNING A ELETRIC PUMP AND THEY HAVE CHANGED THE FRONT COVER.
LOVLEY CAR BY THEY WAY NOT COMITING ON ANY THING JUST HPE ITS RIGHT WOULD NOT LIKE TO SEE YOU HAVE THE WRONG ENGINE INSTALTION.:confused: :confused:


John works for Ford motor Company at the Dunton research centre.

I'm pretty sure he knows what he's doing :D :D :D :D :D :D :D :D :D :D

[RSC 151P]

I am still looking for some one to make a new vehicle loom, if any one knows of any one, PM me.

John[/quote]
ive had quite a few looms done now for mk2 escort rally cars from a guy called frazer vincent, he has done alister mc crea's mk2 and the white GHI mk2 that jimmy mc crea uses, he works as a sub contracter to M-SPORT doing most of there work. his work is amazing. your car looks good enough to warrant a proffesional job. good luck
here is a link to his web site
http://www.motorsportwiring.co.uk/

[John Hall]

Greetings from Finland

HELLO ARE YOU POSITIVE THAT IS A 2.3 BECAUSE THE 2.3 DOES NOT HAVE A MOUNT BRACKET ON THE FRONT WITH THE 2 BOLTS ON THE FRONT COVER.IT HAS A BIG PULLEY UNLESS YOU ARE RUNNING A ELETRIC PUMP AND THEY HAVE CHANGED THE FRONT COVER.
LOVLEY CAR BY THEY WAY NOT COMITING ON ANY THING JUST HPE ITS RIGHT WOULD NOT LIKE TO SEE YOU HAVE THE WRONG ENGINE INSTALTION.

Yep, its definatly a 2.3. In North America you can get a front wheel drive 2.3 Duratec in a Focus. Which is the front cover I have now got fitted to my engine, the the engine mount bracket removed. I will post some pictures of it when I get home this weekend.

Cheers

John

[John Hall]

An update at long last.

Picture of 2.3 North American Focus front chain cover with engine mount machined off.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Front_New_Chain_Cover.jpg

Picture of engine / gearbox and WXM ready to go back in car.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Intake_Side_Assy.jpg

At this point the camera battery died.
The engine is now back in the car and I will post some more pic's tomorrow.

Cheers

John

[paul andrews]

very nice m8:p

[Dave1800BDA]

very good john, looks a very tall engine for some reason

[John Hall]

Dave

Thanks for the comments.

very good john, looks a very tall engine for some reason

The engines a 2.3, so it is 11mm taller in the block.
The other thing that makes it look taller, is the crap 2.3 Ranger cam cover. I have a nice black crinkle coat Raceline cam cover to fit, which is a slim line version. You can see the Raceline cam cover in pictures I posted last year. I have not fitted it in fear of damaging it with the hoist chains, when lifting the engine in.

Regards

John

[John Hall]

Another update of the install, this is the first time the 2.3l has gone in the car. All the other mock up installs have been done with a 2.0l block with a piece of 3/8” plywood sandwiched in between the block and the head to replicate a 2.3. So far the assembly has gone with out any hassle.

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

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

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

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

A colleague from work who is making me the ECU wiring loom came over and measured up the wiring lengths to start making the loom and the auto electrician who is making me the vehicle loom is making a start in two weeks time.

Progress at last.

John

[Dave1800BDA]

looking good John, it all looks at home in there, that manifold looks even better now, good work:D

[grum]

love the look of these manifolds - looks so purposeful :cool:

[graham John]

very neat install there, well done,

cheeRS

[Banishit]

Did you change the water heat outlet pipes over to LHD side for the engine install as it looks like the water rail is on the std engine side ?

Very nice though

[RS2K]

That's very tidy... doesn't look out of place.... keep up the good work:D

[paul spence]

love that,nice neat and tidy:cool:

[John Hall]

Did you change the water heat outlet pipes over to LHD side for the engine install as it looks like the water rail is on the std engine side ?


It does not show it this photographs, but the water rail obstructs where the heater inlet and outlet pipes were originally. I have had to turn the heater matrix over in the heater box so that it comes out the bulk head the other side of the engine were there is more space to attach the heater pipes. I am not happy with the routing of the pipe work; I will have to sort it out when there are more parts bolted to the engine.

John

[Banishit]

or forget the heater ;) LOL

[rwdrs]

It does not show it this photographs, but the water rail obstructs where the heater inlet and outlet pipes were originally. I have had to turn the heater matrix over in the heater box so that it comes out the bulk head the other side of the engine were there is more space to attach the heater pipes. I am not happy with the routing of the pipe work; I will have to sort it out when there are more parts bolted to the engine.

John


Bloody hell, if you don't me saying so!

The matrix can be fitted on the opposite side of the heater box?
I thought it may be like that on LHD MkII's but it isn't!

Well done, I'd never have thought that one can simply fit the matrix to the other side of the box!;);)

[John Hall]

or forget the heater LOL

What….no heater. I am from the south and like my creature comforts!

Bloody hell, if you don't me saying so!

The matrix can be fitted on the opposite side of the heater box?
I thought it may be like that on LHD MkII's but it isn't!

Well done, I'd never have thought that one can simply fit the matrix to the other side of the box!

Thanks.

Yep, the matrix is reversible in the heater housing. I just had to make holes in the heater housing for the inlet and outlet heater hose connections. Cut a hole in the bulkhead for the inlet and outlet and make a blanking plate to cover the original hole in the bulkhead.

John

[rwdrs]

What….no heater. I am from the south and like my creature comforts!



Thanks.

Yep, the matrix is reversible in the heater housing. I just had to make holes in the heater housing for the inlet and outlet heater hose connections. Cut a hole in the bulkhead for the inlet and outlet and make a blanking plate to cover the original hole in the bulkhead.

John



Is there any chance that that housing is used in anything else. i.e. Fiesta, Capri??? With the Matrix on the opposite side?

[marky4]

lovely looking install :)

love that manifold :cool:

[John Hall]

Is there any chance that that housing is used in anything else. i.e. Fiesta, Capri??? With the Matrix on the opposite side?

There might be, but the car has a large gearbox tunnel to take a cossie T5 gearbox. So I just used the non RS2000 heater body that came with the car because I knew it fitted perfectly.

John

[Aaron P.]

sorry to say & this may offend but this complete car gives me a stiffy...:cool: :cool: .....its one of the best conversions ive seen

[rwdrs]

You can tell those American Ford lumps a mile away, I worked on Jags a lot over the last few years, and those castings and the cam covers, are very reminiscent of the V6 motors in the Jags (Probably V6 Ranger motors?), the one-piece cam cover gaskets with the big doughnut style rings to seal around the screw holes.

Let's hope that the 4-Cylinders aren't like the early V6's, i.e. pack up left right and centre. Certainly over here (Germany) the early S-Types ('99) and the early 2.5 X-Types (con rod through block) used to send motors home for a pastime.

The Early V8's (supercharged) were p.. poor too!:eek:

[John Hall]

You can tell those American Ford lumps a mile away, I worked on Jags a lot over the last few years, and those castings and the cam covers, are very reminiscent of the V6 motors in the Jags (Probably V6 Ranger motors?), the one-piece cam cover gaskets with the big doughnut style rings to seal around the screw holes.

Let's hope that the 4-Cylinders aren't like the early V6's, i.e. pack up left right and centre. Certainly over here (Germany) the early S-Types ('99) and the early 2.5 X-Types (con rod through block) used to send motors home for a pastime.

The Early V8's (supercharged) were p.. poor too!

I agree the castings are poor. But things are getting better as Ford & PAG have moved over to the High Pressure Die Cast casting process, which is far superior to the old gravity fead process. If you look at the photo's in the post of the engine build, the cylinder head has a much shiny and smooth finish when comparied to the block. The head is is high pressure and the block is gravity.

All Duratec cam covers are now plastic, as I have said the Ranger cam cover in the lastest pictures is not the one I am using.

Pic of my Raceline one.

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

John

[John Hall]

Another update.

Alternator and starter motor fitted.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Alter_Starter.jpg

Radiator and Bottom Hose fitted.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Bottom_Hose.jpg

Top Hose and Radiator Fan fitted.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Top_Hose.jpg

Throttle Bodies, Fuel Hoses and Cam Cover fitted.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Rad_Fans.jpg

View from the exhaust side
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Dipstick.jpg

Completed installation ready for the wiring loom to be made.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Rad.jpg

View from the front showing how much better and lower the engine install looks with the Raceline camcover.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Front_Rad1.jpg

Things to do next.

It looks like the radiator header tank is higher than the water rail. So I can replace the Mk1 Fiesta thermostat housing and radiator cap assembly on top of the water rail with the Burton remanufactured billet aluminium thermostat hosing they do for the XFlow engines. Which think will look better as I don’t like having two radiator caps in the engine bay.

With the throttle bodies on, I have now ordered 60mm ram pipes from Jenvey and an air filter system from ITG. These should arrive next week and with them fitted, I can then see where the remote oil filter can be fitted and install the oil cooler system.

Thanks for all your comments and questions. It is giving me the enthusiasm to get the car finished for the summer.

John

[Dave1800BDA]

stunning John, very pleasing to the eye this conversion, great quality and attention to detail.

[rwdrs]

Hi John have you made any progress on the heater hoses?

[marky4]

i could just sit and stare at those pictures for ages :cool:

[Banishit]

looks superb install

[Dave1800BDA]

What….no heater. I am from the south and like my creature comforts!



Thanks.

Yep, the matrix is reversible in the heater housing. I just had to make holes in the heater housing for the inlet and outlet heater hose connections. Cut a hole in the bulkhead for the inlet and outlet and make a blanking plate to cover the original hole in the bulkhead.

John

Today I saw a MK2 Escort with a Twin cam engine in, and he had done a similar thing but the water inlet was on the near side on the bulkhead and the outlet uses the original fitment on the off side, sounds funny but looked good

[John Hall]

Hi John have you made any progress on the heater hoses?

I am still working on it. One pipe run is straight forward. From the outlet of the thermostat housing above the alternator to the heater matrix. It is the one from the water rail the other side of the engine thats going to be difficault. I have some ideas..... there is enough space to run a hose between the back of the head and the bulk head but there will be a very tight turn to get the hose on to the matrix. I need to see how much space I have when the ITG air filter is fitted on to the throttle bodies. ITG should be here today. :D

Today I saw a MK2 Escort with a Twin cam engine in, and he had done a similar thing but the water inlet was on the near side on the bulkhead and the outlet uses the original fitment on the off side, sounds funny but looked good

Dave, do you have any pictures ?

John

[Dave1800BDA]

I am still working on it. One pipe run is straight forward. From the outlet of the thermostat housing above the alternator to the heater matrix. It is the one from the water rail the other side of the engine thats going to be difficault. I have some ideas..... there is enough space to run a hose between the back of the head and the bulk head but there will be a very tight turn to get the hose on to the matrix. I need to see how much space I have when the ITG air filter is fitted on to the throttle bodies. ITG should be here today. :D



Dave, do you have any pictures ?

John

sorry John no:(

[John Hall]

This week’s update.
ITG air filter and Jenvey 60mm ram pipes arrived mid week.

The air filter back plate is supplied as a blank and has to be drilled to mount to the throttle bodies and 45mm holes for the ram pipes. I have drilled the mount holes but I need to buy a tank hole cutter to cut the 45mm ram pipe holes.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Ram_Pipe_Intake.jpg

I fitted the two centre ram pipes and tried to fit the air cleaner. But the rams are too long and the air cleaner will not get in between the end of the rams and the inner wing. :( The only solution is shorter ram pipes of 40mm. The 40mm rams will change the shape of the torque curve, making more peak power and reducing the peak torque figure. But being a 2.3 the torque will be still good.:D
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Ram_Pipe_Front.jpg

I removed the rams and fitted the air cleaner with out them to see how it all fitted.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/ITG_Intake_Side.jpg

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

The fuel return line needs relocating on the bulkhead, which is not a problem. Despite the need for shorter ram pipes I am pleased how it all fits.

John

[marky4]

looks lovely :cool:

[Banishit]

some work going into that, top job

[Dave1800BDA]

superb John:D

[Mr Hoarder]

This week’s update.
ITG air filter and Jenvey 60mm ram pipes arrived mid week.

The air filter back plate is supplied as a blank and has to be drilled to mount to the throttle bodies and 45mm holes for the ram pipes. I have drilled the mount holes but I need to buy a tank hole cutter to cut the 45mm ram pipe holes.


John,

I've got a set of tank cutters you can borrow ;)

[Frosticles]

Looking fantastic John Can't wait to see the finished car.

[RS2000&MEXICO]

very very nice.....:)

[John Hall]

John,

I've got a set of tank cutters you can borrow

Rob

You have a PM

John

[Jon Segger]

(Out of interest, where did you get your exhaust manifold from? That looks really nice...)

[John Hall]

(Out of interest, where did you get your exhaust manifold from? That looks really nice...)

Jon

The exhaust manifold was made by Tony Law. He is based near Leeds.

John

[John Hall]

John,

I've got a set of tank cutters you can borrow

Rob

I used a set of tank cutters from work. Job done. Thanks for the offer.

John

[John Hall]

A quick update.

40mm ram pipes arrived in the week.
Back plate holes machined out to 45mm.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/40mm_Rams_Front.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/40mm_Rams_Side.jpg

ITG fitted over 40mm rams.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/40mm_Rams_ITG.jpg

John

[hally]

mint..................;)

[little fella]

what an awesome looking bit of kit

[Dave1800BDA]

can't wait to see this finished, looks the part in there John

[RS2000&MEXICO]

can't wait to see this finished, looks the part in there John


and i bet it will sound the nuts to....:rolleyes: :D

[Frosticles]

An absolute work of art John.

[rwdrs]

I fitted the two centre ram pipes and tried to fit the air cleaner. But the rams are too long and the air cleaner will not get in between the end of the rams and the inner wing. :( The only solution is shorter ram pipes of 40mm. The 40mm rams will change the shape of the torque curve, making more peak power and reducing the peak torque figure. But being a 2.3 the torque will be still good.:D

Can't the torque be brought back to that which you originally invisaged?

The intake resonates in a sinus wave surely? If so this the amplitude of the sinus wave will be replicated one πlater.


i.e. you should be able to shorten those trumpets an extra X (5 mm or so) to get back to the original figures, by moving the place where the positive peak or negative trough of the wave exits the trumpet, I would have thought.

[marky4]

very nice :cool:

[John Hall]

Dave

can't wait to see this finished, looks the part in there John

Will be out and about later this year, but I want to do the Lakes in 2008 with it.:D

rwdrs

Can't the torque be brought back to that which you originally invisaged?

The intake resonates in a sinus wave surely? If so this the amplitude of the sinus wave will be replicated one πlater.


i.e. you should be able to shorten those trumpets an extra X (5 mm or so) to get back to the original figures, by moving the place where the positive peak or negative trough of the wave exits the trumpet, I would have thought.

To dampen out the pulse wave effect caused by the opening and closing of the intake valves, the optimum length of the ram pipes is 90mm for the 2.3 Duratec. Any length shorter than this will be a compromise and will reduce the peak torque produced. But the flip side of this is, the shorter the ram pipe, the peak torque is increased. Also there needs to be a 25mm gap between the end of the ram pipe bell mouth and the inner wing or air filter. There only is 105mm between the air filter back plate and the inner wing, so 90mm rams plus air filter was impossible. I took a gamble with 60mm rams but I could not get the air cleaner to fit. The spec of my engine is a Raceline 250 and should produce a peak value 190 pound / foot of torque at 5000rpm and 250 bhp at 6000rpm with 60mm rams. Jenvey only make 20, 40, 60, 90 & 120mm ram pipes, so I had to go for the next shortest length of 40mm to get it all to fit. Hopefully the torque reduction will not be too large and the extra torque produced by the 2.3 when compared to the 2.0 and the weight of the car will make up the difference. There is a possibility that when the engine comes out for the engine bay re-spray, it will be mapped on Dyno and I can see the true effect of the shorter ram pipes.

John

[BigDave]

I like it A LOT !!!

[rwdrs]

Dave



Will be out and about later this year, but I want to do the Lakes in 2008 with it.:D

rwdrs



To dampen out the pulse wave effect caused by the opening and closing of the intake valves, the optimum length of the ram pipes is 90mm for the 2.3 Duratec. Any length shorter than this will be a compromise and will reduce the peak torque produced. But the flip side of this is, the shorter the ram pipe, the peak torque is increased. Also there needs to be a 25mm gap between the end of the ram pipe bell mouth and the inner wing or air filter. There only is 105mm between the air filter back plate and the inner wing, so 90mm rams plus air filter was impossible. I took a gamble with 60mm rams but I could not get the air cleaner to fit. The spec of my engine is a Raceline 250 and should produce a peak value 190 pound / foot of torque at 5000rpm and 250 bhp at 6000rpm with 60mm rams. Jenvey only make 20, 40, 60, 90 & 120mm ram pipes, so I had to go for the next shortest length of 40mm to get it all to fit. Hopefully the torque reduction will not be too large and the extra torque produced by the 2.3 when compared to the 2.0 and the weight of the car will make up the difference. There is a possibility that when the engine comes out for the engine bay re-spray, it will be mapped on Dyno and I can see the true effect of the shorter ram pipes.

John

I see, but surely if you can't alter the "tuned length" on the intake side you can alter the length of the tube coming out of the back box, here 30-50mm will make minimal difference, only optically or if too short fume out the car:D

I'm sure it'll turn out well enough, but if you've the means the sort out the tuned length of the entire system then you probably can bring back most of the torque;)

[John Hall]

Ordered the fuel injectors from Burtons and arrived through the letter box last Friday. They are Webber Pico 330 cc injectors and are very short. This is the only type of injector that will fit on the throttle bodies and the fuel rail does not obstruct the air cleaner back plate.

Sorry for the poor quality photo, camera would not focus no matter what camera setting I used:mad: .
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Pico_330.jpg

Injectors on the throttles
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Injectors.jpg

Since 2004 all Duratecs have had coil on plug ignition systems. I have wanted to use this system on my project because if I used the twin tower coil wasted spark system I would have to fit the coil tower on the bulkhead and have plug HT leads made to length. Which I do not want to do because I think the coil towers on the bulkhead (near the fuse box) with long plug leads looks messy. Plus the cost of having bespoke plug leads made from Magnecor will cost up to £150. Last week I got confirmation from Pectel that my T2 ECU will drive coil on plug ignition packs. Good news :D .

Coil on plug
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/COP-1.jpg

Coil packs fitted to cam cover
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Coil_Packs.jpg

There is a carbon fibre plate which holds the coils down in position which is being machined to fit and will be ready in a few weeks.

John

[Dave1800BDA]

agree having the set up as yours John less clutter makes it look better to the eye as well.
what was the outcome with the thermostat/radiator cap housing i see youve still got the original type on there.

looks great:D

[marky4]

looking great :cool:

[John Hall]

Dave

what was the outcome with the thermostat/radiator cap housing i see youve still got the original type on there.


The billet Burton one for the Kent / BDA had the wrong orientation (it was completely wrong - the outlet pointed to the bulkhead :(), so it was a no go. I have been told to try the one off of the 1.3 Endura engine which was fitted into the Fiesta and Ka in the 1990's.

John

[John Hall]

Last update before engine bay is stripped for painting on the 8th of May.

Got the carbon fiber plate cut to shape and holes for coil on plug units cut out.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Carbon_Cover.jpg

Carbon plate fitted cam to cover holding coils in place.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Carbon_Intake.jpg

Last few jobs.

Catch tank fitted and screen washer bottle fitted under drivers side front wing.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Catch_Tank.jpg

Strut brace fitted.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Strut_Brace.jpg

I also have fitted the remote Mocal oil filter head and oil cooler in front of radiator.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Oil_Filter_Head.jpg

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

I have ordered Aeroquip -10 Hose and fittings to plumb up the oil cooler circuit. I am waiting the order to clear customs as I bought it in the USA. To buy the Aeroquip I needed in the UK cost £375, to buy from Summit Racing in the USA including shipping, import taxes and VAT £150. The only downside is it takes 3 weeks from order to delivery but for that saving I can wait :D.

Last few pictures. I read a post from Rob “Mr Hoarder” saying that some one of this board now owns his old Harrier. Well……….....

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Harrier_1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Harrier_2.jpg

Its me.

John

[Banishit]

engine bay needs painting ? you got to be joking, I would like that as a finished article LOL

[Dave1800BDA]

great work john, like the blue stripe touch:D

[Frosticles]

Superb attention to detail John.

[ian parker]

fantastic looking car John, stunning attention to detail, i,d get some curtains up if i was you :o

[Mk2grp4]

cool , i like , very nice ,well put togther :cool:

[RabC-RS2-77]

TOP OF THE POPS, that mate !

[pushrod]

Looking real good.
Nice number plate. You sure it's not an old car of Billy Wright (http://en.wikipedia.org/wiki/Billy_Wright_%28loyalist%29) .

:2gunsfiring_v1:

:):)

[RS2000&MEXICO]

this will be so machine :cool:

[Mr Hoarder]

Looking real good.
Nice number plate. You sure it's not an old car of Billy Wright (http://en.wikipedia.org/wiki/Billy_Wright_%28loyalist%29) .

:2gunsfiring_v1:

:):)

Nope, it was mine for 13 years :rolleyes: :D

I've heard the LVF comments before by the way.

It's a good old Norfolk registration number, originally purchased from a Ford main dealer called Sheffield-Garner in Diss Norfolk :thumbright:

[paul andrews]

minter m8,i got a load of bits from summit racing for mine,so much cheaper than over here.they wrote secindhand parts on my packaging to save the import tax as well:cool:

[paul spence]

so neat and tidy,its one of the best installs ive seen:thumbright: :thumbright: MINT:D

[RS 1800]

This is a GREAT car build, I must say!!:)


Conserning the termostat housing, I´ve taken a photo of my two termostathousing taken from mk I and II Fiestas with x-flow engines.

Looks like these housings would fit your Duratec, but the angle seems to be the same as your Duratec housing. The outlet pipe is 30 mm in diameter and there is temperture sending units in these to.

[Mogsmex]

looking lovely as ever John

we'll have to make sure when we drop it off to the painters they get the dash done as well ;) :p

[John Hall]

Thanks for the comments.

The engine bay does need painting, the paint has had a bad reaction with the seam sealer and is flaking off. You can see this on the close up picture of the catch tank and washer bottle cap.

RS 1800
Conserning the termostat housing, I´ve taken a photo of my two termostathousing taken from mk I and II Fiestas with x-flow engines.


Do you have the part numbers for the mk I and II Fiesta termostat housings ?

The Ashley 2 1/2" twin box right hand exhaust system arrived yesterday and it fits first time no modifiations needed.....amazing.

John

[Mr Hoarder]

looking lovely as ever John

we'll have to make sure when we drop it off to the painters they get the dash done as well ;) :p

Thanks for the comments.

The engine bay does need painting, the paint has had a bad reaction with the seam sealer and is flaking off. You can see this on the close up picture of the catch tank and washer bottle cap.

RS 1800


Do you have the part numbers for the mk I and II Fiesta termostat housings ?

The Ashley 2 1/2" twin box right hand exhaust system arrived yesterday and it fits first time no modifiations needed.....amazing.

John

You are still in denial about the dash then John ???? :D :D :D


I've got some aerosol satin black, I think Glyn and myself should come round one day and sort it out ;) ;)

[hally]

very sweet!!!!

[RS 1800]

Thanks for the comments.


RS 1800


Do you have the part numbers for the mk I and II Fiesta termostat housings ?

John

No, I have not..,took them from cars in the breakers yard(in Norway..).

Jorn

[John Hall]

Conserning the termostat housing, I´ve taken a photo of my two termostathousing taken from mk I and II Fiestas with x-flow engines.

Looks like these housings would fit your Duratec, but the angle seems to be the same as your Duratec housing. The outlet pipe is 30 mm in diameter and there is temperture sending units in these to.

After suggestion from RS 1800, I searched the Ford ECAT system for Fiesta thermostat housings and found this one.

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

It is from a 1992 – 1998 1.3 EFI HCS Fiesta and fits a treat.

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

With hose fitted, still needs shortening but I will do this on the final installation.

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

Another niggle off of the list.
Thanks to Jorn

John

[John Hall]

A few pictures of the repainted engine bay and front grille area.

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

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

Glyn and Rob aka Mogsmex and Mr Hoarder showed me the error of my way’s :p , and painted the dash satin black for me.

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

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

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

Nice work lads :D. But no gold Minilites :rolleyes:.

Let the final assembly begin.

John

[marky4]

looks stunning :cool:

good luck with the assembly :)

[graham John]

nice, very nice,
any more updates John ?



cheeRS

[RS2000&MEXICO]

good luck m8....car will be stunning when done...:cool:

[oldskooljoe]

Just seen this thread,stunning work,credit to you:cool:

joe:thumbright:

[John Hall]

Thanks for the comments.

I have been waiting for the cossie T5 gearbox to have its hydraulic clutch conversion completed and I collected it yesterday afternoon.

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

A few pictures of engine bay with brake, fuel and oil cooler braided hoses refitted.

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

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

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

Engine bay is now ready for engine installation. The engine will mounted on the cross member with gearbox attached and lifted up into position from the under side.

John

[Banishit]

very nice John

[oldskooljoe]

very nice,well done!

Joe

[mikers2k]

wow just read all this and its great work

[moonstone mart]

Hi,

Great looking build!!

Can you tell me where you got the hydraulic clutch setup for the T5 please?

Cheers

Mart

[John Hall]

Hi

Thanks for the comments.

Moonstone Mart

T5 hydraulic clutch kit is available from Burtons.

John

[ian parker]

love the work going into this car John, looks stunning, again, love the detail, good luck with the installation:p

[John Hall]

A big thanks to Mogsmex (Glyn) for fitting my new East Kent Trim Headlining.

These pictures no not do Glyns work justice :notworthy:.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Headlining1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Headlining2.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Headlining3.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Headlining4.jpg

Only the rear quarter glass fitted, so lots of bulldog clips holding the headlining in the front and rear screen apertures.

John

[RS2000&MEXICO]

looking stunning john......are you going full trim in the car...?

[Mr Hoarder]

Dash looks nice in satin ; I'm still coughing it up :rolleyes: :D :D :D

[oldskooljoe]

looking good now jhon,well done:cool:


Joe:bigsmurf:

[John Hall]

looking stunning john......are you going full trim in the car...?

Just the headlining, black C pillar trims and door cards.

John

[RS2000&MEXICO]

Just the headlining, black C pillar trims and door cards.

John

sounds nice m8...:)

[graham John]

Just the headlining, black C pillar trims and door cards.

John


ditto the black beastie,


looking good there John, nice detail,


cheeRS

[grum]

very bloody lovely

[bobmk1]

stunning

[marky4]

looking fantastic :cool:

[John Hall]

Engine mounted on cross member and gearbox fitted.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Duratec_Assy1.jpg

Engine Bay ready for install
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Dura_Eng_Bay.jpg

Whole assembly wheeled under the car on a trolley
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Duratec_Assy3.jpg

I had to raise the front of the car by 3 feet to get the engine on the trolley to go under the front spoiler.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Thunderbirds_Are_Go.jpg

Engine etc wheeled under car.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Duratec_Assy4.jpg

Engine hoisted up into position.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Duratec_Assy5.jpg

Job done.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Duratec_Assy6.jpg

John

[RS2000&MEXICO]

looking good john....thats a nice garage you have there loads of space...:)

[docscars]

not be long now john looks the real db

[John Hall]

A knock at the door at 07:15 this morning and the man from City Link delivered this.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Camcoat1.jpg

The manifold has had a ceramic coating on the inside and outside of the pipes and is designed to transmit the exhaust temperature down the exhaust pipe instead of radiating through the walls and heating up the engine bay. This was done by Camcoat and is rated for 1000°C, I am very pleased with it.

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

Picture before coating process, looking a bit worse for wear.

John

[Dave1800BDA]

very nice, i like that:D

[oldskooljoe]

very nice:cool:

[John Hall]

A few pictures of the coated manifold and Ashley exhaust system fitted to the car.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Camcoat2.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Camcoat3.jpg

This picture also shows my new clear laminated screen with blue tint sun strip. Supplied by “Team Ginger Racing” aka Glyn and Rob. Thanks for ordering and collecting the screen for me chaps. :thumbright:

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

A few pictures from the rear and underside.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Rear_Ashley1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Rear_Ashley2.jpg

Last picture of competed underside work with prop shaft fitted.

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

John.

[Frosticles]

I LOVE this car. Fantastic work John, Can't wait to see it.

[Dave1800BDA]

agree with kev, please get it finished soon cant wait till next year, superb work John

[Mk2grp4]

Looking stunning John,will be a beauty when finished :cool:

[oldskooljoe]

looking good now:cool: cant wait to see it:)

[ian parker]

IMO, this is the best resto thread yet, car looks incredible John,:3some:

[mikers2k]

IMO, this is the best resto thread yet, car looks incredible John,:3some:

After yours of course

[John Hall]

Thanks for the comments.
Hopefully, the car will be running later this year and will be at all the major shows in 2008.

After yours of course

I agree.
It is hard to compare Worthers as a restoration to mine.
Which I consider a project to make a Harrier into Group 4 RS1800 road / track day car with a 2.3 Duratec engine installation.

[hally]

must agree looking great!

[John Hall]

A few pictures with door cards, C pillar trims and glass installed.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Int1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Int2.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Int3.jpg

A more few with dash, seats etc.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Int4.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Int5.jpg

Last picture with seats fitted and Racline cam cover fitted to engine.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Int6.jpg

John

[Banishit]

very very nice, thought it would have been ready by now so close

[oldskooljoe]

Amazing work:cool: inside looks really nice now!

looking forward to seeing it next year:)

[paul spence]

The Bollox:d :d

[marky4]

i just love this car, great work :cool: :)

[Mr Hoarder]

Looking very smart John :)

Thanks for the spoiler by the way :thumbright: :D

[grum]

very very nice

all coming together now :)

[mikers2k]

That looks beautiful

[John Hall]

A slight over sight on the axle. I thought it was a Mk1 Capri 50” and it turned out to be a Mk3 Capri 52”. It turns out that all Atlas axles have the same part number on the pigs head whether its Mk1, Mk2 or Mk3 Capri :confused:. This only came to light when I started set the rear suspension ride height and the tyres jammed on the inside lip of the fibre glass arch. So after some more measuring the axle need narrowing by 2” :p.

I put the axle on a pallet and sent it to Fostek Engineering. It arrived back at the weekend and now is a 50” wide Atlas and looks like this :D.


http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/50_inch_Atlas1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/50_inch_Atlas2.jpg

A few pictures of axle fitted to the car :cool:.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/50_inch_Atlas3.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/50_inch_Atlas5.jpg

John

[mikers2k]

Looks great

[andym]

Very Nice.....

[marky4]

looks tasty :cool:

[graham John]

yes, coming along very well,



cheeRS

[paul spence]

very,very nice:D

[Northern Bloke]

Looking very nice indeed :thumbright:

and I know all about that "jamming on the arches" bit - Tom received my axle shortly after I tried fitting the rear wheels :D

[rs1800mk2]

I would like one for Christmas :violent1:

[docscars]

:cool: :cool: not b long now John looking great

[SHIFTY]

Great work mate, looking good :cool:

[John Hall]

Under the bonnet is just about finished.

I fitted the throttle and speedo cable and made the camcover and crankcase breather hoses and fitted them to the catch tank.

The vehicle and engine management wiring looms are being worked on, the vehicle loom has been trail fitted once to check the modifications are correct and is now being bound in black plastic over braid.

The only outstanding job to do under the bonnet is the heater matrix hoses. I am hoping SFS will be able to make me a set of moulded silicone hoses to match the radiator ones. I will do a separate post on these hoses once SFS say they can do the job.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Eng_Bay1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Eng_Bay2.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Eng_Bay3.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Eng_Bay4.jpg

A few pictures on the car on its wheels with the narrowed atlas fitted. The ride height is correct. Adjustments are need to the panard rod and camber, castor and tracking. I can do the panard rod in the workshop but the front suspension settings will have to be done on a floor with better levels.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Harrier_3.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Harrier_4.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Harrier_5.jpg

John

[Frosticles]

That is one gorgeous car John. Engine install looks factory. Fantastic work.

[graham John]

agree with Frosticles, excellent job there, well done,

cheeRS

[Dave1800BDA]

i just cant wait to see this car john, looks stunning:D

[grum]

thats lovely - detailed and clean looking, nothing clustered :thumbright:

[custom219v]

A pat on the back is needed there! Gr8 work:thumbright:

[RStu]

What a car! :cool:

[Mr Hoarder]

http://www.rwd-escort.co.uk/images/robdoyle/harrier6.jpg

This seems such a long time ago :(

[John Hall]

Way back in February, on page 5 on this post.
http://bbs.rallyesportescorts.co.uk/showthread.php?t=8620&page=5

I was explaining why the heater matrix inlet and outlet spigots are on the passenger side of the bulkhead. This was due to the spigots failing against the water rail and the heater hoses would have been very close to the exhaust manifold if they were left in the original position.

Not to bother with a heater matrix circuit would have been the easiest option but there are good reasons to have a heater matrix circuit plumbed in. The main reason is the heater matrix circuit is the coolant by-pass circuit. Which means when the thermostat is closed during engine warm up, there is a reduced coolant flow around the engine. This allows a stable engine warm up with the heat rising around the engine uniformly and stops head gasket failure which is a common fault with alloy engines during warm up. My other reason is that a steamed up windscreen is a pet hate of mine so I had to find a way to plumb in the heater circuit.

To resolve this, I flipped over the heater matrix in the heater assembly so that the spigots came out the other end of the heater assembly. Looking in the engine bay with the engine stalled this makes the heater matrix spigots now on the intake side of the engine and with no obstructions.

My next problem was the routing of the matrix hoses. The bottom heater hose is straight forward from the thermostat housing by-pass to the bottom spigot on the heater matrix. The top heater hose is a bit more convoluted due to the return to the engine is on the water rail, on the other side of the engine above the exhaust. Which means running a hose behind the engine over the Bellhousing. After many attempts with bits of hose, connectors and hose clips which looked crap. I decided that a bespoke set of silicone hoses moulded to the route were the only option.

A few hours surfing the net, I found that SFS Performance Hoses in Luton do make bespoke hoses to order. But the cost of designing and making the hose mandrels or forming tools is very expensive. So I made the mandrels myself and SFS made the hoses from my mandrels and this is how it was done. This took me six months to get to the finished hoses fitted to the car and has to be the most infuriating and frustrating part of this project so far.

1) Go to B&Q and buy some domestic plastic plumbing pipe with the outside diameter of the plastic being the inside diameter of the heater hoses, in the case 15mm. Using a heat gun and pipe benders, form the plastic pipe to the heater pipe routing. These will be the mandrels made in plastic.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Heater_Hose_Buck1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Heater_Hose_Buck2.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Heater_Hose_Buck3.jpg

This is what they looked like removed from the engine.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Heater_Hose_Buck5.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Heater_Hose_Buck4.jpg

2) Next was to find a toolmaker to make the mandrels about of 15mm solid bar using the plastic mandrels as a pattern.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Heater_Hose_Mandrel_1a.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Heater_Hose_Mandrel_2b.jpg

The large square bosses are welded on the end of the mandrels are so that the mandrel can be clamped in a vice and held firmly to remove the hose after the hose is made.

3) Then the mandrels were sent to SFS and these are finished heater hoses.

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

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

And here they are trail fitted to the car with the hose clamps loose.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/SFS_Hose1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/SFS_Hose2.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/SFS_Hose3.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/SFS_Hose4.jpg

I am very pleased how they look and they match the radiator hoses which were made by SFS but supplied by Ralloy :D. Also, I own the mandrels and SFS will make extra sets to order….. This could be the beginning of a cottage industry for me :rolleyes:.

John

[grum]

super

well done

[johnylock]

luvly jublie:cool:

[plentysideways]

you'd never know that it didn't come with that engine in it from new just by looking, would you? superb job

[John Hall]

First update of the year.

Installation of the modified vehicle loom is now completed. The engine now cranks and the oil cooler circuit is primed and oil pressure has been achieved.

A few pictures of the boot, which is now complete.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Boot_Elec_1.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Boot_Elec_2.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Boot_Elec_3.jpg

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Boot_Elec_4.jpg

Battery cable and loom from rear bulkhead

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Rear_Bulkhead_Elec_1.jpg

Engine bay picture with wiring loom, oil filter / cooler circuit and fuel hoses. Which looks very complicated and messy but it will not be seen when the throttle bodies and air filter are fitted.

http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Front_Bulkhead_Elec_1.jpg

The large hole next to the loom grommet is for the ECU loom which is not yet finished.

The ECU loom should be ready early March and the car running by Easter.

John

[lee bishop]

excellent job john, its nice to see someone go to such effort to get something just right, top work

[Dave1800BDA]

looks complicated in the engine bay, still looking good tho john

[DAZZER]

That is one AWESOME car you have there, when do you hope to have it finished.

[John Hall]

That is one AWESOME car you have there, when do you hope to have it finished.

Thanks for your comments. I am confirmed for the Lakes Tour. I want it running by Easter. Which will give me about two months to Map the ECU, set up the suspension and sort out any gremlins that might occour.

John

[RS2000CUSTOM]

Nice detail on the spare wheel clamp (amongst other things - lol)

Do tell what you used or is it yet another bespoke item ?

[John Hall]

Nice detail on the spare wheel clamp (amongst other things - lol)

Do tell what you used or is it yet another bespoke item ?

Spare wheel post and clamp supplied by Ralloy. Here is the link.

http://www.ralloy.com/productdetail.asp?RALNo=RAL103A


John

[graham John]

very nice build there John,


cheeRS

[rs1800mk2]

I have changed my mind I do not want one - I need one. Very nice indeed.

[RS2000&MEXICO]

stunning :cool:

[Martin]

Looks awesome John, looking forward to seeing it @ The Lakes Tour :cool:

[paul spence]

Quality

[pushrod]

Absolutely fantastic level of quality and detail. I never even knew you could get hoses custom made like that. Nice one.

[fast eddie]

looking sweet! love to see it in the flesh!!!!!
Edd.

[marky4]

fantastic job you have made of this car, great work :cool: :cool:

[Deepest Blue]

excellent job john, its nice to see someone go to such effort to get something just right, top work

Agree with Bish Bosh.

Stunning work John :thumbright:

[John Hall]

A few photo’s of the cars progress over the last month.

View from drivers door – big thanks to Mogsmex (Glyn) for spraying the gear stick gator housing diamond white to match the gear box tunnel. :D
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Dash_Front_Drv1.jpg

Dash – showing RS light illuminated at ignition on. Which has been configured as a low oil pressure warning light, as the RS dash only has the oil pressure gauge.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Dash_Front_Drv2.jpg

View from passenger door – I used a Ford Puma gear knob as it has the same gear shift pattern as the cossie T5 gear box.
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Dash_Front_Pas1.jpg

Front passenger foot well showing vehicle loom and Life Racing F22 ECU. The coil of wires in the centre of the photo are the 7 wires which will have a plug fitted to connect the vehicle loom to the ECU loom, which I am still WAITING for. It was promised for 1st of March but it has got delayed due to the ECU and wiring loom suppier’s wife having a baby and is on paternity leave.:mad:
http://i213.photobucket.com/albums/cc23/Hall_Effect/Mk2%20Escort/Dash_Front_Pas2.jpg

The car is completely finished, just need the ECU loom, fit the throttle bodies and air cleaner and start mapping the ECU.

John

[mikers2k]

WoW that looks amazing

[John Hall]

ECU loom was delivered today :D. I am going to install it over the weekend and the auto electrician will splice it into the main vehicle loom next week.

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

I had to move the car today, here is a few pictures of it in the spring sunshine.:cool:

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

http://i213.photobucket.com/albums/cc23/Hall_Effect/Harrier_8.jpg

A big thanks to Glyn for helping to push the car back in the workshop. :thumbright:

John

[johnylock]

its quality mate ! with a superb eye for detail ..:dropmouth:

[graham John]

looking very nice,

well done



cheeRS

[paul spence]

ver,very nice john:D

[Martin]

looking very nice :thumbright:

[oldskooljoe]

stunning:cool: