My flat front RS build (not rebuild!!)

[mk1rally]

Managed to finish off the alloy panels this week.

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

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


IMG_0317 by jerrythegerman, on Flickr

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

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


IMG_0319 by jerrythegerman, on Flickr


IMG_0318 by jerrythegerman, on Flickr

[mk1rally]

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

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


dash by jerrythegerman, on Flickr

[mk1rally]

Brake plumbing and wiring loom in the engine bay.

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


Engine bay by jerrythegerman, on Flickr


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

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


inside by jerrythegerman, on Flickr

[andym]

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

[south west restorations]

nice dash set up there .

[mk1rally]

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

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

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

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

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

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

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

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

Result!!

So here it is, home in its rightfull place.


engineexhaustside by jerrythegerman, on Flickr

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

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


enginein by jerrythegerman, on Flickr

[mk1rally]

Been getting a few things done now.

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

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


tonylaw by jerrythegerman, on Flickr

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

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

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

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

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

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


photo by jerrythegerman, on Flickr

[kas750]

Nice work.Did you get in touch with Karas?

[mk1rally]

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

[kas750]

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

[mk1rally]

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

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

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

Busy unit, easily distracted too!


thegarage by jerrythegerman, on Flickr

So back to the 'scort.

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

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

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


carbsin by jerrythegerman, on Flickr

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

[mk1rally]

Well its been slow progress due to issues with the Cooper S rally car and events close to each other. Escort took a bit of a back burner but back on with it now.

Finally finished the engine bay wiring and location of various items. Took ages as it a bit bespoke and the shell didnt have all the holes in it where a production RHD car has (its a LHD shell).

It also had square headlights so I had to buy some second hand metal lamp holders to allow me fit circular ones. Bit of head scratching and sussed it and ended up using the aux light RS2000 wiring loom to switch on the cibies when they are fitted.

Cleaned up the grille and fitted it up.

Just the quarter bumpers to fit at the front and lamp steadies.

Also managed to pick up a couple of set's on Mag Minilites in good nick so that I can keep my R888's for track days and these mags are fitted with A2's, very period.

Anyway, a new picture. The front end.

frontphoto by jerrythegerman, on Flickr

[mk1rally]

Finished off the engine bay, only thing I am not happy with is the throttle cable route, seems a bit stiff and is not pinched anywhere.

Will copper slip the cables and see if that helps. Failing that I will need to change the linkage for one that sends the cables forward to the rad and then round.

Anyway, I'm happy with it for now.


latestenginebay1 by jerrythegerman, on Flickr


latestenginebay2photo by jerrythegerman, on Flickr

Cleared up the garage a bit and spun the car round. working on the boot area now, so need to work out how to fit the GP1 Tank (asked for help on another thread) as I didnt get the straps with it. I can work out where the straps go on the tank but not how they attchached to the body or how they tightened, just want it to look right.

Also got to fit the battery (to be bought!), spare wheel fittings and the fuel pump.


sideshot1photo by jerrythegerman, on Flickr

[Mikethepanel]

Looking good david

[marky4]

some great work there car looks lovely