Mk2 2.3 Duratec

[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

John

[5hane]

hey


just read the thread start to finish very nice

looks tonnes better in real life too!



cant wait for the feature too

[John Hall]

Shane

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

Cheers

John

[5hane]

Shane

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

Cheers

John

very small world lol !

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

[marky4]

what a stunning car

[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]

2009 Up Date

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 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.

John

[John Hall]

2009 Update Part 2 - So late it's 2010

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. 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.





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.



Shows attended in 2009.

Lakes Tour 2009 - Won “Car of the Tour”



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]

Bias Pedal Box and Front Brakes

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.

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



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.



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.




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.





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



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.



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.



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