My Danish escos history and build
16-05-2008, 11:37 PM
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DANISH cosworth abuser
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Join Date: Aug 2004
Location: Holbæk, denmark
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My Danish escos history and build
Well to make a looooong story short, i started my ford playyard with an S2 rs-turbo with 210bhp in 98, and that started my passion for ford´s and tuning.
In martch 2000 i bought this escort cosworth bt 93´ model lux non leather, we found it in germany as an ex ford diretion car @ 128k km totally standard.
Still having the S2 tuned, had me to realise that it kicked the cossie arse bigtime, so after having the cossie for 3 weeks, i decided to have a 330kit installed........ shortly after that, i sold the rs-turbo
Now, after winning denmarks fastest car 3 year in a row(almost) and having burnet a few pistons(to much boost) it was time for the engine to let go, and i startet my first real cossie build.
It was std bottom end with cosworth race pistons 7,2:1 p&p head/inlet bd-14´s 2wd manifold with turbonetics t34 and fixit gearbox i felt like the bomb, until a year later when a lost a spark ploug and totalled the engine
This time i had to buy ewerything.
Got me a used 1time skimmed sierra cos 4x4 head complet with ewerything in it, brand new 200 motorsport block and new used cranck as the old one was to bend to use.
So started to search the net for different build ups so i could find out what i wanted, and ended up with a "sweedish" kit.
I startet with buying verdi longer rods, cp pistoms custom made, sweedish pelnum with bigger throttle, peter g shortpipe manifold with 38mm wg, GT35 / 1,06trim, "secret cams" and custom exhaust system.
After some discussion i ended up with buying HALTECH enginemanagement system top model E11 version 2, cause @ that time, the std dident cope with more than 450bhp.
the old top went out with the new to get it cut up, so the head guys could find the limits to the ports, to get the maximum out of the new head, and we discussed how i wantet it to be, together with the new exh-manifold.
Cranck rods block and pistons and clutch/flywheel went to a cylinder service company to get it borred and balanced knifeedge and lightened.
Same time i started to buy the upgrades to the transmission and new i/c from pro-alloy plus the new custom fuel system.
The whole idea wae that i wantet the engine to be as light as possible.
Got the engine started the first time september 2004, after mounting the new management system from haltech, but something was´nt right.
The mapper were having problems with getting it to go straight, and it resulted in a valve in the top broke off and smashed the piston end head in cylinder4 and also the cam was dead
We couldent find any fault but found out that the timingbelt must have jumped a tooth
Well nothing to do but buy some new parts and get on with it then
Got the head welded up, new seats guides and valves, new cam and new piston(block had survived)
Mounted it all up again, and this time it worked, mapper was happy and 4 hours later he caleed with some good and bad news, good news was "this car is insane, i have newer seen anything like it" bad news was @ 0,8bar(340bhp) the oilpump blew up..........
This was the time, when i really wantet to give up...
I let the car stand in the garage for almost a year, before i took her apart to se what had happend, pheew, only 2 bearings and the oilpump, nothing else...... i thought....
The turbo was dead, metal from the dead cam had stopped the oil supply.... what a shitty year..... AGAIN!!
Again i had to get it all together, got the car to the mapper, but only to see more problems, as the haltech was acting all stranged.
We then spend a few months sourcing the errors but in the end i decided to scrap the management.
Now Gordon from streetracers has been wery helpfull and go me set up with an omex 710 management system, which im just about to set up this wery minut.
Whish me luck guys
Now, i havent got pictures of everything, but if someone want, then i can try to fix it as soon as i can.
Old look
Newest pic of the car
OLD engine
NEW engine just finished 1. time
Dead head
Dead piston
New bottom end
Bottom end build up
PererG short pipe manifold
cp piston verdi rod complet weight
Knife edge cranck
Inlet
Exhaust
In martch 2000 i bought this escort cosworth bt 93´ model lux non leather, we found it in germany as an ex ford diretion car @ 128k km totally standard.
Still having the S2 tuned, had me to realise that it kicked the cossie arse bigtime, so after having the cossie for 3 weeks, i decided to have a 330kit installed........ shortly after that, i sold the rs-turbo
Now, after winning denmarks fastest car 3 year in a row(almost) and having burnet a few pistons(to much boost) it was time for the engine to let go, and i startet my first real cossie build.
It was std bottom end with cosworth race pistons 7,2:1 p&p head/inlet bd-14´s 2wd manifold with turbonetics t34 and fixit gearbox i felt like the bomb, until a year later when a lost a spark ploug and totalled the engine
This time i had to buy ewerything.
Got me a used 1time skimmed sierra cos 4x4 head complet with ewerything in it, brand new 200 motorsport block and new used cranck as the old one was to bend to use.
So started to search the net for different build ups so i could find out what i wanted, and ended up with a "sweedish" kit.
I startet with buying verdi longer rods, cp pistoms custom made, sweedish pelnum with bigger throttle, peter g shortpipe manifold with 38mm wg, GT35 / 1,06trim, "secret cams" and custom exhaust system.
After some discussion i ended up with buying HALTECH enginemanagement system top model E11 version 2, cause @ that time, the std dident cope with more than 450bhp.
the old top went out with the new to get it cut up, so the head guys could find the limits to the ports, to get the maximum out of the new head, and we discussed how i wantet it to be, together with the new exh-manifold.
Cranck rods block and pistons and clutch/flywheel went to a cylinder service company to get it borred and balanced knifeedge and lightened.
Same time i started to buy the upgrades to the transmission and new i/c from pro-alloy plus the new custom fuel system.
The whole idea wae that i wantet the engine to be as light as possible.
Got the engine started the first time september 2004, after mounting the new management system from haltech, but something was´nt right.
The mapper were having problems with getting it to go straight, and it resulted in a valve in the top broke off and smashed the piston end head in cylinder4 and also the cam was dead
We couldent find any fault but found out that the timingbelt must have jumped a tooth
Well nothing to do but buy some new parts and get on with it then
Got the head welded up, new seats guides and valves, new cam and new piston(block had survived)
Mounted it all up again, and this time it worked, mapper was happy and 4 hours later he caleed with some good and bad news, good news was "this car is insane, i have newer seen anything like it" bad news was @ 0,8bar(340bhp) the oilpump blew up..........
This was the time, when i really wantet to give up...
I let the car stand in the garage for almost a year, before i took her apart to se what had happend, pheew, only 2 bearings and the oilpump, nothing else...... i thought....
The turbo was dead, metal from the dead cam had stopped the oil supply.... what a shitty year..... AGAIN!!
Again i had to get it all together, got the car to the mapper, but only to see more problems, as the haltech was acting all stranged.
We then spend a few months sourcing the errors but in the end i decided to scrap the management.
Now Gordon from streetracers has been wery helpfull and go me set up with an omex 710 management system, which im just about to set up this wery minut.
Whish me luck guys
Now, i havent got pictures of everything, but if someone want, then i can try to fix it as soon as i can.
Old look
Newest pic of the car
OLD engine
NEW engine just finished 1. time
Dead head
Dead piston
New bottom end
Bottom end build up
PererG short pipe manifold
cp piston verdi rod complet weight
Knife edge cranck
Inlet
Exhaust
Last edited by cossiemanden; 17-05-2008 at 12:25 AM.
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