Back on the road!
After not using the Escort for some time I decided the best way to get the car up and running again was to rebuild it back into a fast road car - keeping some of the track modifications like the uprated transmission, brakes and safety features, but also adding comforts such as better seats, a heater and things that would make it easier to live with on the road - like mirrors and lower suspension.
The first bits I bought are a pair of modern reclining seats
Bits update: Jan 2007
Bought a new rear panel from Ebay, the old one was strong enough, but it had been repaired in the past. Best to get rid of the filler and start off with a nice straight panel for the road. I don't think we'll need to do any more bodywork other than the prep for the paintwork. The car is solid and has held up well.
Bits update: Feb 2007
Crystal headlights, mk1 front bib spoiler (Speedshack)
Completely new door, window and glass trim set (East Kent Trim)
Front and rear alloy door cards, alloy rear firewall panel (Prepfab), door cards are to be trimmed in suede/alcantara.
Used RS front struts (www.turbosport.co.uk forum member) - being sent direct to Gaz for coilover conversion.
Bits update: March 2007
Bought some new bits :-) After much head scratching over whether to keep the great XE engine and carbs, or whether to go a different route on the road build, I finally went for Cosworth power. The Vauxhall C20LET turbo was a contender as it would have been an easy slot in job - but the Ford badge won out in the end. The engine is from a member on the www.turbosport.co.uk Ford forum. Here's the rundown on the bits:
200 Series block with clutch & flywheel
Sierra 4x4 Cosworth head, intercooler, and exhaust manifold
4x4 L8 ECU and stage 3 chip, dark green (803) injectors, 3 bar MAP sensor
Hybrid T3 running .60 A/R compressor (it's a big one!), actuator
Plus all the loom, coil etc. There's a T5 box too, but it's in bits and needs rebuilding. (eek!)
Bits update: August 2007
Things are progressing slower than I'd like with the car - mostly a combination of apathy, lack of funds, a complete lack of motivation when I get in from work on an evening. I've also been searching almost everywhere on the planet to try and find a source of 5th gear cogs for the T5 gearbox... but it seems that Borg Warner (or Tremec who actually make the box now) no longer manufacture the gear used in the Cosworth version of the box. Consequently, unless I want to have the box prefessionaly rebuilt or fit a totally new gearkit it's basically now a pile of useless junk... so I've had to start searching for a useable T5 gearbox instead - easier said than done... they're just not hanging around any longer when they come up for sale. Anyway, I've been buying a few more bits here and there to try and get everything ready for when I start on the car again. Here's the latest set of new parts:
Alloy header tank
Alloy fuel swirl pot
Alloy battery tray
T5 Gearbox in good working condition
T5 Cossie bellhousing
New Atlas crown wheel and pinion set for the diff in a 3.56:1 ratio
Panhard rod and tower kit for the rear axle (from RallyDesign... and a terrible fit, see images above)
Used, but good RS2000 multi-leaf rear springs
I also got the converted RS front legs back from Gaz and am very pleased with the quality!
Also started fitting seat bars to mount the new el-cheapo ebay bucket seats. I'm just using some box section steel and decent gauge flat plate where they attach to the body
The full spec sheet with prices and suppliers for the complete road-car build process can be found here in the download section (part.xls - Microsoft Excel format)This page updated: 13/August/2007