escort cosworth full build update 28/5/11 , its home

[xr4x4rs]

little bit more, as its so close to xmas i havnt bothered ordering anything incase it never turns up, sp started on the rear diff so here it is nice and filthy back plate off to look inside the diff 3.62 so at least i know its the correct diff driveshaft joints out, i wanted to see if one of them would fit in the front diff so i can get rid of the std pop joint that always break but its slightly too big, but i think if it coudld be machined down i could get it too work, but ill look into this at a later date all cleaned up and a nice bit of paint on it alls i need to do is get some new bolts for the diff late, and send the drive flanes in for elcetro plating, so this iwll be after xmas now also as i mentioned earlier on in the thread i was thinking of cutting the boot floor out for easier access to the fuel pump incase ieve need it well, out came the jigsaw!!! before after just got to give it some sealant underneath and a lick of paint, then get some carbon sheeting and some rivinuts

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[the youth]

brave man taking a jigsaw to an esc cos!

it's coming on great btw

steve

[Simmo]

Good stuff!!!

[xr4x4rs]

Originally Posted by the youth

brave man taking a jigsaw to an esc cos!

it's coming on great btw

steve

that is true mate, and i was sweating a bit doing it lol, but if the fuel pump does fail at least i dont have to drop tanks to get to it, i can just tae a cover off and its there

[RSLUBBY]

Nice work cant wait to see it done mate

Cheers

Ian

[xr4x4rs]

little bit more done

hole is no all seam sealed up and painted again







and i cleaned my stub axles that go in the diff, you can see the difference between the one that hasnt been cleaned, but both are ready now for elcetro plating, just my batts went flat in camera

[Glenn.]

Nice work mate.Its nice to see another escos getting restored.Keep,you the good work.

[xr4x4rs]

little update, over xmas ive been geting things ready for electroplating for the new year, so started off with my steering rack and dismnatling it







all dismantled ready



cleaned up and ready for the platers



steering racked all cleaned and painted





and today, i decided i need a vice lol, so went and bought this one



next was rear driveshafts



gaitors cut off as ill replace with new ones



had to buy some circlip pliers for this clip (copper colour ring in middle)





joints all off, these wont be sued as they have a lot of play in them for my liking, so ill get some new ones



grease al cleaned off



then i gave it a good clean as best as i can to get a decent finish from the platers, didnt want to have them blasted due to being a rough finish, you can see the diffference bewteen the cleaned on and the one that needs to be done

[Glenn.]

Nice work mate i will be watching this post till its finished.

[fezzajsy]

looking good

[Kezmo]

Niceee!

=)

[xr4x4rs]

another little update

my abs pump arrived, so i started to strip this down to be cleaned







i was a bit nervous at this bit as i didnt know if it had pressure in it or not, luckily it never



all stripped down



started to mask and paint things then



got some stuff back from electro plating so was time rebuild it



also, i noticedf all the wiring had melted, so this item was changed from a spare unit i was using for bits mine was missing



new one



starting to take shape as a pump again





others bits ive had electro plated









rear diff all built back up, just need to put the tag on as i forgot, got new bolts from ford aswell



steering rack next



ends back on, loctited in and then punched back to hold them



new gearse applied on the ball joint ends and inside the rack as original stuff was a bit dry



gaitors back on with new cable tie



all pipes back on aswell





overall its come out better than id imagined

abs pump all fitted up aswell, just need to fit accumulator, but this was being painted at the time, also if anyone has a abs cap i need one as 2 of mine have snapped

[Dunc Maclean]

keep up the top work mate, love a good escos build thread!



Dunc

[fezzajsy]

luving this project

[xr4x4rs]

thanks lads, some things are taking longer than planned as im still getting stuff out the way from xmas and new year

[Tev]

looks good fella

[svony]

Thanks for the updates, you're buildup is few steps ahead of mine and it keeps me motivated. I just took delivery of a ABS unit yesterday, don't think I have the balls to take it aparts as you did yours. Really nice meticulous work...

[Glenn.]

Sweet its getting there slowly.

[El Grand Tomismola]

Mint stuff - where you sending your stuff for electro plating?

[xr4x4rs]

i just take it down to a local company that does it usually Ł20 a go, so before i go down i make sure what i have is a load of stuff to be worth the money

[El Grand Tomismola]

I could do with finding a place like that myself.

[Sonic Boom]

i just take it down to a local company that does it usually Ł20 a go, so before i go down i make sure what i have is a load of stuff to be worth the money

Which company is it mate? Couldn't be to far a journey for me to make as it only takes half an hour to get to yours from mine.
Rich

[Little_Hoss]

cant believe you got the shell for 5k

going to be awesome when finished mate!

[RS-Stian]

Quality work mate, love this resto thread. Do you have any finis code on the new bolts to the diff house?

[Moonstone Mart]

Originally Posted by RS-Stian

Quality work mate, love this resto thread. Do you have any finis code on the new bolts to the diff house?

Stian,

The diff plate bolts i got are F1625498 and they were 67p each from my Ford dealership


Mart.

[Sanchez_]

looks good u old tart

[xr4x4rs]

lol, thanks lads

jay im not that old, not even in my 30s yet!!!

little hoss, i got more than a shell for that money, dont forget alls it was missing was engine, ecu, exhaust and brakes lol

i also found out it was one of the press cars and there is a picture of it as one of the launch cars going round brands hatch in a book called the cosworth fords just waiting on the book to turn up

[xr4x4rs]

Originally Posted by Sonic Boom

Which company is it mate? Couldn't be to far a journey for me to make as it only takes half an hour to get to yours from mine.
Rich

coma plating mate

[Rs Adz]

this coming on very well keep it up

[andy escos]

should be minty fresh when finished ya buftyna love the detail m8 top work.

[xr4x4rs]

another little update

ordered a full set of poly bushes off burton wednesday and they turned up today

1st disaster was they never sent the main beam bushes and on the reciept said out of stock
i even asked if they had them all in stock before i amde the ordered

so with half the day gone and i had a lad on his way round from gloucester to buy some rouse bits i was a bit stuck as i wante dthe beam in today

so quick phone call to lloyd of passionford as i seen he was advertising some bushes, and he sold me the 2 main beam bushes, these are not the usual bushes aswell, they may aswell be metal there that strong

so i know have all my bits

so the beam all ready laid out, colours are different as i wanted it bright and shiney



the bushes



the tough bushes



couple of little bits from ford



my friend matt (jona bona) came round to help me fit these beam bushes as no where was open with a press due to the time of day, so 3.30pm he was here, got the beam in the vice and made our own little press machine with the vice and some old suspenion plates and cups, couple of attempts 9trying not to scratch the beam ) and they popped in lovely

we then went about fitting the beam, what a nightmare, the std bolts were to short as the bushes were taller, so quick phone call to llyod again and he said use engine cradle bushes to get them in and swap over to std bolts once plates were on, we tried everything frst with jacks and nothing

so when we looked we realised the arms had to go, so this was a simple job bar we put the arms on backwards, so left to right and right to left , soon enough changed over and went for another attempt

this did not go well, as the beam is heavy now and still couldnt get it in, so i bolted the diff on for some leavage, and we finally got the beam in after a lot of swearing and messing about and was 6.30pm when it finally went in

so couple of little pics of it in place with all new bolts







so alls i need knwo is a diff mount, driveshafts,wheelbearings, brakes, braklines,abs sensors and suspension and the rear is done, im going to try and order most of it next week, and try and find some abs sensors

but its getting there now and its getting closer to its wheels, doesnt seem much but i think it does, and im never taking this beam out again as its too much grief, roll bar will be on tomorrow if i can be arsed to get out bed

[COS 22]

looks well, keep the pics coming !

[martrs]

Thats looking cool rich

[xr4x4rs]

Originally Posted by martrs

Thats looking cool rich

tried ringing u earlier, give us a ring when you get 5 mate

[fezzajsy]

[Twellsie]

looking good Rich, which powder coaters do you use these days, i have a few bits i need doing?

[Tev]

Originally Posted by Twellsie

looking good Rich, which powder coaters do you use these days, i have a few bits i need doing?

you havent got time to send things to the powder coaters, hurry up and change your cam cover over

[xr4x4rs]

one not far from your work mate, up bayton road, duno the name but there on the same little road as just tyres i think the tyre place is called

[TrevCos]

Wish I had the skills to do things like this, that is looking fab.

[tezmanian devil]

smart project you got goin here dude, if only i could afford a esc cos
keep up the good work anyway chap, i'll see ya tomorrow