My Escort - Updated 28-Nov-2011

[Mike Rainbird]

INTERIOR: Full leather Recaro interior: Stack ST8130P* - Speedo / Rev counter / oil pressure / fuel pressure / water temperature (before radiator) / oil temperature / battery / fuel level / odometer / tripmeter / manual lap timer. All idiot lights replaced with custom items. Exhuast Gas Temperature gauge - Defi* Water temperature gauge (after radiator) - Defi* *Peak memory recall and alarm warning on all readouts, with record and play-back on APEXi and Defi items. Boost pressure gauge - APEXi 2.5 bar*. Electric sunroof. Three position boost control - 1.6 bar, 1.9 bar or 2.2 bar. Willans Harnesses. Momo gear knob. Pectel Monitor mounted in centre of dash. WHEELS & TYRES: Wheels: Compomotive MO cast alloy, 8" x 18", ET15mm offset. Tyres: Front: 245/35ZR18, currently Dunlop Super-sport Race Front: 245/35ZR18, currently Dunlop Super-sport Race BRAKES: Front: AP Racing 378mm (15") CP3700-1010/11G8 grooved and ventilated discs (fully floating) with gold anodised aluminium bells. AP Racing CP6235 6-pot differential bores, liquid-cooled, WRC callipers, and stainless-steel braided hoses. Ferodo DS3000 (CP6235D46) pads. Rear: AP Racing 315mm (12.4") CP3580-64/5G8 grooved and ventilated discs wth gold anodised aluminium bells. AP Racing "Ex-works" Grp A, Ford Motorsport CP3620 4-pot callipers with titanium pistons and stainless-steel braided hoses. Ferodo DS3000 (CP3215D50) pads. System: Hydraulic, dual-circuit with vacuum servo assistance and Teves ABS. Reyland hydraulic handbrake actuation. ENGINE: Type: Ford-Cosworth YBP Capacity: 2228cc Bore / Stroke: 93mm/82mm Compression ratio: 7.27:1 Max. power: 544bhp @ 7448rpm @ 31 PSI** Torque @ max. power: 382lb.ft Max. torque: 450lb.ft @ 5010rpm @ 31 PSI** Power @ max. torque: 429bhp Specific output: 244.5bhp per litre. Power / weight ratio: 380bhp/tonne. Cylinders: Four, in-line. CP 93mm pistons. Cylinder head: Works spec medium ported head (carried out by Nick Waples), with race spec long duration solid lifter cams. Block: Cast iron (200 Series), WRC tri-metallic head gasket and long-studded (10) Bottom end: Farndon 82mm crank, WRC high pressure oil pump, Autoverdi 137mm rods. Valve gear: Four valves per cylinder (35mm inlet / 31mm exhaust), 3-angle valves / seats operated by belt-driven twin overhead camshafts and solid lifter tappets operated by Isky valve springs. Big wing (5˝ litre) baffled sump and Bailey crankcase breather kit with braided hosing. Fuel and ignition: Electronic fuel injection with Pectel T6 ECU, Pectel monitor, water injection, Ford Motorsport leads, distributorless ignition system and ALS. AGP 071 plugs, four Bosch 1000cc injectors and 3 bar MAP sensor. Live mapped on engine dyno by Harvey Gibbs Cooling: Pro-alloy Motorsport 50mm radiator, Pro-alloy auxiliary radiator (see below - this cools water for cylinder head), SPEC-R header tank, swirl pot and water-cooled power steering reservoir. Induction: K&N 2wd panel filter inside modified standard Sapphire air box with carbon fibre Grp A Escort airbox lid, T04E turbo (60 trim) with Maram 247 shaft 360° bearing etc, -31 actuator, Pro-alloy 65mm "super-wide" RS500 air-to-air intercooler and water injection (2 x 0.6mm jet). Boost controlled by Ford Motorsport air injectors. Installation: Front, longitudinal Exhaust: Hayward & Scott 4" downpipe splitting into twin 2˝" system with oval tail pipe (four silencers). Water injection SUSPENSION: Front: Independent by LEDA gas filled adjustable dampers with Eibach 350lb springs. Macpherson struts, set to 3° negative camber, 2mm total toe in (fully adjustable rose jointed modified standard TCAs). Standard 29mm anti-roll bar with polyurethane bushes. Rear: Independent, by semi-trailing arms, LEDA gas filled adjustable dampers with Eibach 171lb springs and standard 22mm anti-roll bar. Grp A 6° Ahmed Bayjoo rear beam set to 2°45' negative camber and 3mm total toe-in. Polyurethane rear axle bushes. Rear bumpsteer: Bump 60mm - 0.030" toe in 50mm - 0.023" toe in 40mm - 0.015" toe in 30mm - 0.009" toe in 20mm - 0.005" toe in 10mm - 0.003" toe in Droop 10mm - 0.001" toe out 20mm - 0.002" toe out 30mm - 0.003" toe out TRANSMISSION: Type: Front-engine, four-wheel-drive Gearbox: MT75, five-speed with Swedish (Fixit) gear kit. AP six-plate paddle clutch with Reyland hydraulic actuation. Front diff: Quaife ATB in thickwall casing, with 3.9 drop gears by Barra Motorsport Rear diff: Quiafe ATB in standard casing with 3.9 final drive by Barra Motorsport Internal Ratios (FIXIT Gearkit): 1st 3.00:1; 2nd 1.99:1; 3rd 1.33:1; 4th 1:1; 5th 0.825:1; Reverse 2.75:1; Final drive 3.9:1 giving 22.88 mph/1000rpm in top gear with 245/35x18s. Maximimum speed in gears at 8000rpm (rev limited to 8500): 1st 50mph 2nd 75mph 3rd 113mph 4th 151mph 5th 183mph STEERING: Type: Power-assisted rack-&-pinion Lock-to-lock: 2.4 turns BODY / CHASSIS: Type: Pressed-steel monocoque, based on conventional Sierra / Escort, in two-door style. Chassis construction: In steel, as part of monocoque Dimensions: Length: 4211mm Width: 1727mm Height: 1425mm Wheelbase: 2551mm Front track: 1453mm Rear track: 1472mm Actual Weight: 1425Kg* (on road) On track weight: 1395kg* (tool kit, spare wheel and rear MDF shelf removed). *Measured with half tank of fuel, wet weight without driver (75kg).

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[Mike Rainbird]

Quaife thick wall casing


Quaife ATB



At Bedford








At the Nurburgring


At Snetterton


At ND 2004

[Mike Rainbird]

Latest acquisition

[Mike Rainbird]

Rods and pistons have arrived :

Auto Verdi rods (same ones as used in the 800bhp Per Eklund Pikes Peak Saab), safe to 9500rpm (which is just as well ).





CP Pistons:


Should all start being built up over the next few weeks.

[Mike Rainbird]

Cam cover machined for Mountune sensor, prior to painting (crackle finish as per existing item).

[Mike Rainbird]

WRC Breather:

[Mike Rainbird]

[Mike Rainbird]

Mountune roller barrells machined and matched to ports (were 24mm, now taken out to 27.5mm and matched perfectly to head). Thanks to Tim at SCS .

[Mike Rainbird]

[Mike Rainbird]

[Mike Rainbird]

Just had the engine on the dyno, but when it got to 600 lbs/ft of torque with a T3 turbo, it blew the standard head gasket completely out .

[Mike Rainbird]

New fuel pump bracket with built in swirl pot:






Bracket with fuel pump fitted:




Fuel pump and swirl pot fitted to underneath car:

[Mike Rainbird]

Engine being built up:






Mod to engine mount taken from Grp A cars - bolt size increased from M8 to M10 (I had one of the offside ones shear off at the Ring last year).

[Mike Rainbird]

Harvey has asked me to ask Passion Ford which way he should mount the remote oil take-off .

Horizontally


Vertically


Or diagonally?

[Mike Rainbird]

Engine almost ready to go on dyno .

[Mike Rainbird]

[Mike Rainbird]

Engine mount and steering coupling heat shield:






Ready to bolt in

[Mike Rainbird]

Fuel system all connected:


Heat shield to protect pump from exhaust:




Aeromotive fuel filter:


Transmission all in place, including Alumec diff strengthening plate:


Turbo heat shield:


Coil-pack bracket:


Turbo heat shield in place:




Still only half way there . Fiddly bits take the longest!


Group A carbon airbox lid arrives tomorrow !

[Mike Rainbird]

More pictures, but the REALLY annoying thing is that this work of art WON'T be on the car in time, due to the fact that I have to move all the HID gubbins for the 2wd base to fit, and I just don't have enough time, so the OE airbox will have to go in place until I get back . I expect Paul Ripley will be cranking one off right now .

[Mike Rainbird]

Nearly done .

[Mike Rainbird]

After finally aborting trying to get Mountune to make the required 93mm liners, Perfect Bore were approached in the middle of May, drawings sent off to them and on Wednesday this week, they turned up . I only wish that we had approached them initially, as they turned everything around from SCRATCH in less than 4 weeks .

Behold, 93mm Nikasil liners, don't look much do they?





Now it is the small matter of getting them fitted to the block, so should be a matter of weeks and then the car will be ready again .

[Mike Rainbird]

[Mike Rainbird]

Should be ready for Ford Fair .

[Mike Rainbird]

[Mike Rainbird]

[Mike Rainbird]

Due to the oil cooler going in the above location (see previous pictures), this meant that the washer bottle had to be relocated, so I had the Pro-Alloy boys make me up a huge tank that takes care of the WI, windscreen washer, rear screen washer and headlight washer duties.

It retains the level sensor from the original washer bottle, which now meens I have a warning for when the water injection reservoir is running low . Practical and efficient.

[Mike Rainbird]

As posted in the general section, the transmission woes turned out to be the CWP as suspected:





Simple fix, which is being carried out by Bara Motorsport as I type this .

[Mike Rainbird]

A few updates .

Harvey didn't really like the Aeromotive pump, as it really needs the controller on a road car, so he changed it for a pair of standard pumps:








I also decided to have my manifold coated, whilst the turbo was away with Vince having some top secret AVA mods .

[Mike Rainbird]

I've just had my Mar-m 247 shafted T4 converted to full roller-bearing core.

This required the shaft being sent away to be ground down by the peeps that do lots of this kind of machining for F1 teams .

It has also had the secret mods carried out to the turbo housing to improve the flow (a la Euan's turbo), but I cannot post pictures of these at the moment, as I promised Alan I would not .

Enjoy the pictures of what I can though. And please be aware that you can have YOUR normal turbo converted to full roller bearing core as well - improves spool up by some 3-400rpm! If you want a quote to do yours, just ask .

[Cossie-Iain]

What kind of power will you get?
Thats some awesome looking gear you have for your motor.
Top work.

[15D]

Awesome
One of the very best EsCos's out there

[Lee Reynolds]

An awesome, well sorted Escos Mike. Nice one!

[trevCOSS]

looking good mike, nice to see the pics back on here again.

[BrianEscCos]

Just incredible that that much can be done to an already great car, superb example of how to do something the right way. Well done and keep showing us.

[wimble]

pretty much my dream spec !!!
keep the pics comeing

[ScORTED]

wow...

[hai07222]

Looks great

[Red16]

Fabulous car Mike... subtle but devastatingly usable

One thing i'm really suprised at is your on the road weight of 1425kg with a half tank of fuel... i had my Evo V on the weighbridge at work and in full road trim with nigh on a full tank of fuel it was 1410kg... i always though the Escort was a fair bit lighter than the Mitsi

[carlo]

Top thread mike

[kik1.6se]

That looks superb.

Out of interest how do you measure the rear bump steer and what figures would you expect for a standard Escort Cosworth?

Kirk