My project Escort 'maxi' Officially Dead. Now being broken.

[GTechR]

Bit bored so I decided to put it all up... It started out as a Mk5 Escort XR3i, I have to be fair, a good 80% of the work was carried out before I got the car, I originally started out building a Mk2 XR2, but it became so involved that i'd spent far more money than it warrented and i'd still only got a semi prepped shell, so I gave that to a guy who builds hot rods (I'd had the car since 1990 and couldn't bare to see it go to a scrappy) and started looking for a new project, I did actually buy a mk2 RS2000 X Pack, but after sitting down and looking at what I wanted to do, it soon became apperent that the RS could well go the same way as the XR, so I decided to move it on and look for somthing else, which bring me back the escort... Originally built to compete in the Ford Saloon Championship, the car is built to a very high standard, but the owner was then offered a full works spec focus so decided to move the XR on... Lucky me!! The car is currently running a standard 1800 Zetec approx 130 BHP, but that will soon be replaced with an RS2000 I4 lump built to the Maxi Rally Car spec, it's been mapped to approx 230bhp but is capable of 280, at that level it was totally unusable on the road so it was backed off so it is more user friendly, it still has a rev limit of 8500 and in the XR it should prove to be more than capable... Imediate plans are to upgrade the brake system and get the engine up and running, which is sorta how I came across Fin as I need an Exhaust system to marry up to the maxi spec manifold. Once I have the car running I will turn my attention to the bodywork, I have a few tricks up my sleve and an idea in my head how i want it too look, as it's a Mk5 I don't want it to be a Maxi replica ( The Maxi was a Mk6) But I want it to nod in the Maxi's direction, so think along the lines of arch extensions, Different bumpers, and some more suitable wheels. A few Pics of the car as it was ( I've already started the makeover) The interior will pretty much stay as it is... Although I will have to run it with a second seat at some point as my little Lad wants to go in it... And the Engine, soon to be fitted... Chassis and Safety •Safety Devices 6 point roll cage with harness bar and door bars. •Safety Devices plumbed in mechanical fire extinguisher (nozzle in footwell and engine bay, operable internally and externally) •Cobra Imola race seat •Polycarbonate windows with sliders fitted to doors Polycarbonate rear quarters and boot windows •FIA electric cut off switch (operable internally and externally), Ignition switch and starter button. •Varley Red Top 25 competition gel battery •T100 Lap Timer (100 lap memory) •Bonnet and boot motorsport pins and catches Engine •RS2000 I4 2ltr 16v •Cosworth High Comp Pistons (11:3 Comp ratio), Arrow Rods, F2 Maxi Spec head, with Maxi Spec Cams •Pectal T2 ECU c/w Full loom •Jenvy 45mm Throttle Bodies •Tony Law Maxi Spec Tubular Manifold •Approx 230 - 240bhp and 8800rpm rev limit •Custom made exhaust - 97db's at 4000rpm (No CAT) (soon to be changed) Future Mods... Pipercross Airbox, Side exit exhaust system. Suspension + Brakes •AVO coilovers, Sport EVO GTZ kit •Fully polybushed throughout •Sparco rear strut brace •E-Tech alloy front strut brace •Red Dot grooved front discs •Mintex pads front and rear •16"x 7" Team Dynamic Multispoke •Rear disc brakes Future Mods... Brembo 4 pot's with 300mm discs, Escos 16" x 8" OZ Monte Wheels Transmission •RS2000 gearbox reconditioned by Geartorque •Uprated 3rd Gear Synchro •Quaife ATB (Automatic Torque Biasing) differential •Techniclutch uprated sports clutch •New driveshafts I did intend to get the engine in and running, but due to various happenings I've decided to get the bodywork sorted first... So I'll try and explain as I go, as already stated I wanted to loosely base the car on a Maxi but being a Mk5 I cant really do a replica, so i've taken on board a few different ideas to give a totally one off look. This is the car i'm loosley basing it on. This is the first dummy fit of the wing, those of you that remember the XR2 you 'may' recognise the arch extensions... Basically as they are designed for a Mk2 Fiesta i'm gonna have to extend them... The next few pics show my first attemp at extending the arch... And then onto dummy fitting the rest of the kit... Next onto modding the metalwork, I hate it when you see massive arches and then look under them to see the original bodywork still there. if your gonna fit big arches have them functional... Marking the metal Once cut the lip was pulled out... and the other side And finally I've been fettling the front... From the front it looks a bit odd but once i've been at it with the matting and filler i'm 'hopeing' it'll look ok. I then started fiberglassing the front bumper, I got the initial shape 'just about' how I wanted it. What I did then is take the bumper off and reinforce the rear of the moulding, then start to shave the front off, to place the final layer of matting on, before I start to fill it. I've also started on the skirts, got them roughly fitted, and started to design the lower section of the arch that will be moulded into the skirt. Please excuse the Special K Box :whistle: i tried a few different designs, but decided on this. Again if you look beyond the fact it's a cereal packet, you can see the shape it's gonna take. Now the only problem I have is, the space I have looks MAHOOOOSIVE... So I thought I'd just bung a wheel on to see, and I think even if it's slammed, i'm gonna struggle to fill the arch up, so i'm considering selling the OZ's :dazed2: What do you think? **Wheels now gone** Chopped the rear arches out ready for the new fiberglass ones... Just need it welding up (if anyone fancies helping?) not my stongest point. Anyway thats the boring bit, i've also been on with the bumper... First two are with the first coat of fibrefiller. Next few are with the filler rubbed down... And the last few with it 'very roughly' mounted to see what it looks like... I decided to have a go at making some brackets to fit the brembo's. Please bear in mind i've used a set of ST170 discs, which are 300mm dia' (the FRS are 324mm so they will fit perfectly (well fingers crossed)) i'm just using the to get the spacing right. And this is the bracket, I just need to get it replicated in a thicker Section of Alloy, and hopefully it should be ok!! Now about uptodate, i've started to weld the new arches in the rear... Shit pics i'm affraid, but you get the jist. Bear in mind this is only my second ever attempt at welding.

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[mark]

looks cool

[cossie690]

lookin good m8.. keep us posted....

[the saint]

good work mate keep it up

what wheels are you going to run now then budd???

[danrs2k]

[SimonT]

you kept that quiet mate!

[wim klomp]

Looks absolutely great

keep posting the updates

[GTechR]

Originally Posted by SimonT

you kept that quiet mate!

You never asked

Cheers lads

[marco polo]

looking good

marco

[AquariousRS]

looking good.

Only problem that i can see so far is with the brakes, as the ST170 300mm disks have a different offset to the FRS 324mm.

I think the ST disks have a 30mm offset whereas the RS disks have 40mm.

Tim.

ps, i want your wheels.

[GTechR]

Originally Posted by AquariousRS

looking good.

Only problem that i can see so far is with the brakes, as the ST170 300mm disks have a different offset to the FRS 324mm.

I think the ST disks have a 30mm offset whereas the RS disks have 40mm.

Tim.

ps, i want your wheels.

Cheers mate, Yep the bracket on there at the mo is just the template, the final one will be fabricated to take the Offset into account.

[AquariousRS]

good man

[GTechR]

Originally Posted by the saint

good work mate keep it up

what wheels are you going to run now then budd???

Sorry mate I didn't see your question

No idea really i'll have to see whats about when i'm ready for wheels, I want to go with some sort of motorsport wheel, if money was no object then it would be TH2's all day long, (best looking wheel ever imho) but i doub't i'll find any second hand

[GTechR]

pretty much now upto date...

[Charlie Chalk]

I love the Maxi styling


Keep it up

[GTechR]

Right i've been doing a few bits n bobs... (not as much as i'd like, but i'm getting there)

I've been teaching myself to weld, and i've finally finished the first rear inner arch...





As you can see pretty it aint, but it is functional, and to say that it's my first real attempt at welding i'm quite happy with it...

I've also started on the outer section, i'm not gonna plate the entire arch as it's gonna have a fiberglass wing over it so i'm just gonna spot weld the top bit and plate the front bit... if that makes sence.




I've also been doing some cosmetic bits n bobs, i'm partially mounting the bumpers on bonnet pins cuz to be honest there the best solution i've found, these are the mounting points...






And i've binned the old wing mirrors for these...





And finally I fitted the passenger seat, which was a bit of a headache as the fire extinguisher was located there.


But i've relocated that to the front footwell...

I'll fit a footmount infront to stop it being kicked.

And this is the seat fitted, i've mounted it as far back and low as possable. (cuz thats how they have em in propper rally cars - lol), just got to get another harness.






Thats it for now...

[749steve]

top stuff

[danrs2k]

[Rab]

[GTechR]

cheers guys

[smitsturbo]

lovely project mate

[RONNIE AMIS]

love it mate hats off to you for doing the welding all yourself when youve never done it before i keep thinking about them mirrors for my 3 door, where did u get them from??

cheers

[massivewangers]

Brilliant, just brilliant! Nice to see someone doing something with the often neglected MK5 Escort. Looks like it's coming on a treat now. Can I book a passenger ride when it's all done

One thing though, is it staying red? Was just thinking, if it is, I'd prob see about having something done to change the colour of the seat centres, as the blue clashes a bit. Probably the least of your worries at this point though

[GTechR]

Originally Posted by RONNIE AMIS

love it mate hats off to you for doing the welding all yourself when youve never done it before i keep thinking about them mirrors for my 3 door, where did u get them from??

cheers

Demon tweeks of all places mate...

re: my seats, not sure what colour im going yet

[Ex-Finesse]

Excellent work

[marco polo]

looks good

fancy doing mine

[john16v]

thats coming on well mate. how much r the brackets for the brakes? tempted to get some as that would solve my problem of fitting big brakes under 16's

[GTechR]

Originally Posted by marco polo

looks good

fancy doing mine

I'll get back to you on that one mate....

Originally Posted by john16v

thats coming on well mate. how much r the brackets for the brakes? tempted to get some as that would solve my problem of fitting big brakes under 16's

I designed (for want of a better description) them myself mate, wait till I make sure they actually work, then i'll look into getting some made.

[adamS2RST]

Nice project this! Coming along really well and some nice fabrication work there mate. Top stuff

Are you sure Ally is upto the stress of caliper mounting? even the thick stuff is pretty soft, plus threading is a nightmare as the steel bolts will just chew it up, I'd be tempted to use lump of steel like the cossie brake to RST brackets are.

Project looks awesome though, and I bet that engine sounds sweet, how much did it set you back if you dont mind me asking?

[Brian]

Excellent project mate


Brian

[GTechR]

Matt, good point about the alloy, something i'll look into.

As for the Cost. I could tell you, but the wife 'may' at somepoint read this, and I would like to keep my tesicals attached to the rest of my body

[Dan]

Looks great mate! Fair play to having a go by yourself! Keep up the good work!

Will look great i'm sure!

[Reid]

looks awseom mate, where did you buy the arches from? (probably been askd already but its alot of reading lol)

[GTechR]

Originally Posted by Reid

looks awseom mate, where did you buy the arches from? (probably been askd already but its alot of reading lol)

They are meant to be for a Mk2 XR2, I'm having to adapt them ( quite a lot as it's turning out )

[M Brian]

looks ace gary

[massivewangers]

Originally Posted by GTechR

They are meant to be for a Mk2 XR2, I'm having to adapt them ( quite a lot as it's turning out )

Are the arches part of an aftermarket kit then? Curious as never seen them before. Good for the job though

[GTechR]

Originally Posted by massivewangers

Are the arches part of an aftermarket kit then? Curious as never seen them before. Good for the job though

MCR Bodykit mate...

Melv Cheers matey... you still on with the XR?

[GTechR]

Thats the kit on Grahams Mk1 it's virtually the same.

[M Brian]

I still have it but everything is on hold at the moment. time constraints are worse than ever at moment. am going to have to insure the mk2 turbo tho as my NCB runs out in couple weeks after 2 years!! maybe inspiration!

very impressed at how youve got going on this project!!