RS1600i / S1 rep Rebuild....new wheels 23/05/2010

terribletaj · 20-02-2010, 10:28 PM

Hi

Brought this car nearly a year ago now, brought as a non-runner apparently only needing a turbo, but after getting it home there was alot more it needed to have done,so the decision was made to rebuild it fully:

Advertised as having a 2.1ZVH forged engine, LSD box etc etc, however after closer inspection it appeared to have a completly standard bottom end that had broken piston lands on 3 of the pistons, standard non-LSD box, no RS1600i front anti-roll bar.

So gave it a quick clean and started to strip it back to a bare shell, found a little rust on the drivers sill, but other than that no rust what so ever. After 4 rusty RSTs this shell was a god send

Cleaned all underneath and applied 6L of anti-stone chip and 4L of white hammerite leaving it looking like this:

Refurbished the Koni adjustables, new Apex springs, Full polybushes, Sandblasted and powdercoated the tie bars and wishbones, rear disc conversion and stud and nut conversion too:

All fitted up:

Taking inspiration from twins engine bay, gave it a full seam weld and smoothed alot of it off:

New steering rack, new TCAs, Brake bars blasted and powdercoated:

Painted the floor:

Resprayed the shell in the whitest of the diamond white shades:

Gas strut conversion for bonnet:

Started to refit the bodykit:

Rear disc set-up:

Refurbished tank from an XR3i EFi:

Brought a rebuilt IB5 box and had a RST LSD fitted to it:

After finding out the ZVH was no good, I bought and rebuilt a 1.6CVH EFi engine:

Fitted into the bay:

Fitted side glass:

Inlet fitted, was orginally going to run OFAB so this was fitted at the time:

Exhaust and rear bumper fitted:

Airtec front mounted intercooler fitted:

New screens fitted:

Turbo and alternator fitted:

Underside shot:

Building up the engine bay:

Fitted a RS1600i grille to keep its origins:

Fitted dash, Full interior is now fitted but can't find the pics:

Then the problems started, was orginally going to run OFAB management, fitted it all in, but could not get it running right, eventually decided to strip it all out and fit weber management, brought a OKC kit of the bay. So pull it all off again:

Will be getting the last bits I need of Jano next week, so hopefully after 10 months of work I will be able drive it!

Full spec is:

RS1600i shell
Full Series 1 kit
1.6 cvh, rebuilt to standard spec with minor headwork, ARP bolts and ACL bearings throughout
Cosworth 2wd T3 turbo and downpipe
Mongoose exhaust system with 3.5" tailpipe
Airtec pro series front mounted intercooler
Cosworth managment with L8 ecu
Bosch 803 dark green injectors
3 Bar map sensor
SFS full silicon hose set
Bailey breather
IB5 gearbox with LSD
Ap racing 4 paddle clutch
Mk5 clutch mod with alloy quadrant
Koni adjustables with Apex 30mm springs
Stud and nut conversion
Full polybush kit
RS1600i front anti-roll bar
Puma gear-linkage
Escort cosworth alloys with 205/40/16 yoko paradas
300mm ST170 discs with mondeo mk3 front calipers
Rear disc conversion
Full refurbished series 1 interior with uncracked dash
Zenon headlight conversion
LED bulbs throughout

Will update as more work gets done.

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Zetecfiesta · 20-02-2010, 10:32 PM

id just put the series 1 grill in, looks mint though!

cossiejsy · 20-02-2010, 10:34 PM

Wow thats is Stunning

terribletaj · 20-02-2010, 10:38 PM

Quote:

Originally Posted by Zetecfiesta

id just put the series 1 grill in, looks mint though!

thanks, the series 1 grilles never fit right, and I prefer the look of the 5 slat one, although everyone keeps telling me to fit the series 1 grille.

Quote:

Originally Posted by cossiejsy

Wow thats is Stunning

thanks

Ginger Will · 20-02-2010, 10:56 PM

Nice

Rab · 21-02-2010, 12:10 AM

That is stunning!!!

turbocabessex · 21-02-2010, 12:36 AM

stunnin

njietro · 21-02-2010, 12:50 AM

great car!

rst in breaking · 21-02-2010, 01:09 AM

lovely motor mate and job looks great

terribletaj · 21-02-2010, 10:09 AM

thanks everyone, makes all the work worthwhile.

jonny s2 · 21-02-2010, 10:21 AM

awesome work pal!
but put the s1 grill in will look loads better with the style you have gone for,i love it

smitsturbo · 21-02-2010, 10:52 AM

lovely mate well done

jonboisescort · 21-02-2010, 10:56 AM

lovely motor mate

jay · 21-02-2010, 11:03 AM

spot on mate!!

Glenn. · 21-02-2010, 11:41 AM

I like that alot.Its well mint.

tosher71 · 23-02-2010, 11:23 PM

well done pal, looks awsome. get the standard wheels back on.

muz · 24-02-2010, 09:56 AM

That looks proper tidy mate. I'd be tempted to leave the S1 decals off. Looks great without them for a change.

terribletaj · 24-02-2010, 02:49 PM

Thanks for the nice comments everyone

Quote:

Originally Posted by muz

That looks proper tidy mate. I'd be tempted to leave the S1 decals off. Looks great without them for a change.

Yeah the stripes will be staying off, might put the little RS ones on, but I like the clean and uncluttered look.

Got the last bits for the cossie managment off jano yesterday, going to fit it all up this weekend hopefully.

xr2madman · 24-02-2010, 08:33 PM

hi there top job mate looks brill where did you hide your wires

Twins · 24-02-2010, 08:42 PM

Looks fantastic ,bay looks great smoothed

10th_racer · 24-02-2010, 08:46 PM

Quote:

Originally Posted by muz

That looks proper tidy mate. I'd be tempted to leave the S1 decals off. Looks great without them for a change.

me too, that looks stunning!

muz · 24-02-2010, 09:49 PM

Quote:

Originally Posted by terribletaj

Got the last bits for the cossie managment off jano yesterday, going to fit it all up this weekend hopefully.

Good lad

andy130 · 24-02-2010, 10:02 PM

looks mint mate but copper brake lines look dirty?

terribletaj · 24-02-2010, 10:42 PM

Quote:

Originally Posted by xr2madman

hi there top job mate looks brill where did you hide your wires

Most of them have gone through the inner wing into rubber tubing then back into the bay where the wings meet the front panel at the bottom, will get a pic as it will make more sense

Quote:

Originally Posted by andy130

looks mint mate but copper brake lines look dirty?

Think it might just be my phone, as there brand new copper lines, thinking of painting them black to match everything else.

Quote:

Originally Posted by muz

Good lad

Yeah, was just having so much problems with the OFAB stuff, plus your limited to what you can with it. Hopefully the cossie managment will be up to the job

muz · 24-02-2010, 11:06 PM

It will do everything you need it to do and more mate.

terribletaj · 25-02-2010, 05:41 PM

Finished work early today so cracked on with the escort.

Got the inlet, fuel rail and injectors, cosworth throttle body, all sensors, new dizzy, throttle cable, top pulley set-up fitted. Got most of the loom in too, just need to renew the fuel pump wiring and connect up the power to the ECU and fit the bottom pulley, then we're good to go.

Pic of todays progress:

danny_boy699 · 26-02-2010, 10:39 AM

looks good mate keep the updates coming

cossiejsy · 26-02-2010, 12:31 PM

looking very nice

Zetec_mk4_XR3i · 26-02-2010, 05:01 PM

work of art mate - well done

terribletaj · 13-03-2010, 04:12 PM

Little update, It's done!

Had a few teething problems but with some help from Jano she's now running sweet, just need to get some miles on her then can turn up the boost!

Here's some pics:

muz · 13-03-2010, 04:48 PM

That really does look cracking mate! Hats off to you. Love it!

terribletaj · 23-05-2010, 05:56 PM

Little update,

Got fedup of the constant rubbing and poor handling with the escort cossie wheels, so decided to changed them for something better sized. Went with some 7x16 compomotive 6 spoke MOs:

Drives so much better now, can put my foot down without it weaving all over the road now. Also the headgasket and pistons rings are dead so brought another CVH, this one will be fully forged with a decent head so should make some decent power! Will update when work starts on it.

smitsturbo · 23-05-2010, 06:13 PM

looks nice mate well done

harvcore · 23-05-2010, 09:48 PM

ace

oibren85 · 23-05-2010, 10:30 PM

Love it, really nicely done, not a super fan of the wheels. But then again think they look amazing on RS7! top work.

Twins · 23-05-2010, 10:44 PM

Looks great on them wheels ,would be tepmted to get a dmb sticker set down the sides if it were mine

terribletaj · 24-05-2010, 05:18 PM

Thanks for the comments

Quote:

Originally Posted by Twins

Looks great on them wheels ,would be tepmted to get a dmb sticker set down the sides if it were mine

I did actually have a set fitted afew weeks ago, just didn't look right for some reason, so keeping the clean look for now.

jonny s2 · 25-05-2010, 10:23 AM

awesome craftmanship mate

H7 CYA · 25-05-2010, 11:02 AM

That really does look good, loving the new wheels too! Top work mate.

stembo21 · 25-05-2010, 11:18 AM

nice car mate

20-02-2010, 10:34 PM	#3
cossiejsy PassionFord Post Whore!! Garage is empty, add now Trader Score: (0) Join Date: Feb 2005 Location: St Helier,Jersey Posts: 7,589 Rep Power: 15	Wow thats is Stunning __________________ Dont like my drivin then stop watchin me Jersey Rs Owners Club member of the daytime pf talk bollocks and random shite club #65

21-02-2010, 12:10 AM	#6
Rab Fucking superstar........ Garage is empty, add now Trader Score: (0) Join Date: May 2004 Location: Argyll.... It's lonely... Posts: 12,601 Rep Power: 20	That is stunning!!! __________________

21-02-2010, 12:36 AM	#7
turbocabessex shit happens Garage is empty, add now Trader Score: (1) Join Date: Jan 2009 Location: essex Posts: 1,926 Rep Power: 5	stunnin __________________

21-02-2010, 01:09 AM	#9
rst in breaking PassionFord Post Whore!! Garage is empty, add now Trader Score: (2) Join Date: Oct 2005 Location: chingford, london Posts: 7,822 Rep Power: 14	lovely motor mate and job looks great __________________ BREAKING MY ZETEC TURBO ESCORT!!! MK1 Escort wanted!!!

21-02-2010, 10:21 AM	#11
jonny s2 PassionFord Post Whore!! Garage is empty, add now Trader Score: (12) Join Date: Apr 2009 Location: west coastcustoms Posts: 4,180 Rep Power: 7	awesome work pal! but put the s1 grill in will look loads better with the style you have gone for,i love it __________________ power is nothing without control

20-02-2010, 10:32 PM	#2
Zetecfiesta PassionFord Post Whore!! Garage is empty, add now Trader Score: (0) Join Date: Jan 2005 Location: Westhoughton Bolton Posts: 3,934 Rep Power: 11	id just put the series 1 grill in, looks mint though!

20-02-2010, 10:56 PM	#5
Ginger Will Too many posts.. I need a life!! Garage is empty, add now Trader Score: (0) Join Date: Nov 2006 Posts: 663 Rep Power: 6	Nice

21-02-2010, 12:50 AM	#8
njietro retr0<3 Garage is empty, add now Trader Score: (0) Join Date: Dec 2008 Location: Finland Posts: 33 Rep Power: 0	great car!

21-02-2010, 10:09 AM	#10
terribletaj Wahay!! I've lost my Virginity!! Garage is empty, add now Trader Score: (0) Join Date: Jun 2006 Location: London Posts: 65 Rep Power: 6	thanks everyone, makes all the work worthwhile.

21-02-2010, 10:52 AM	#12
smitsturbo PassionFord Post Whore!! Garage is empty, add now Trader Score: (0) Join Date: Oct 2005 Location: aberdeenshire Posts: 7,246 Rep Power: 14	lovely mate well done __________________ www.sitechracing.co.uk

21-02-2010, 10:56 AM	#13
jonboisescort I'm Finding My Feet Here Now Garage is empty, add now Trader Score: (0) Join Date: Jul 2009 Location: christchurch dorset Posts: 141 Rep Power: 3	lovely motor mate __________________

21-02-2010, 11:03 AM	#14
jay Too many posts.. I need a life!! Garage is empty, add now Trader Score: (0) Join Date: Aug 2004 Posts: 738 Rep Power: 8	spot on mate!! __________________ Back in a cossie ________________ Matt Lewis Motorsport - Cosworth & RS Parts Specialist-Worldwide Mailorder. Walsall - West Midlands - WS4 1RR Tel;01922 692424 - Fax; 01922 685810 Genuine Trade Enquiries Welcome email; sales@mattlewismotorsport.co.uk New Weshop; www.mattlewismotorsportonline.co.uk Ebay Shop;http://stores.shop.ebay.co.uk/Matt-Lewis-Motorsport

21-02-2010, 11:41 AM	#15
Glenn. Professional Waffler Garage is empty, add now Trader Score: (1) Join Date: Jul 2006 Location: Darlington county durham Posts: 27,983 Rep Power: 33	I like that alot.Its well mint. __________________ NORTHEAST/NORTH YORKSHIRE ALL FORD MEET ORGANISER pm for details.

23-02-2010, 11:23 PM	#16
tosher71 15000 Garage is empty, add now Trader Score: (0) Join Date: Oct 2009 Location: carnoustie Posts: 36 Rep Power: 0	well done pal, looks awsome. get the standard wheels back on.

24-02-2010, 09:56 AM	#17
muz Wye Valley Hardcore 1988 Ford Escort Trader Score: (0) Join Date: May 2005 Location: Hereford. West Mids Posts: 3,346 Rep Power: 10	That looks proper tidy mate. I'd be tempted to leave the S1 decals off. Looks great without them for a change. __________________ "BRAVERY IS THE CAPACITY TO PERFORM PROPERLY EVEN WHEN SCARED HALF TO DEATH"

24-02-2010, 08:33 PM	#19
xr2madman Wahay!! I've lost my Virginity!! Garage is empty, add now Trader Score: (0) Join Date: Apr 2009 Location: leicester Posts: 52 Rep Power: 3	hi there top job mate looks brill where did you hide your wires

24-02-2010, 08:42 PM	#20
Twins 15K+ Super Poster!! Garage is empty, add now Trader Score: (14) Join Date: Sep 2004 Location: ESSEX Posts: 15,591 Rep Power: 23	Looks fantastic ,bay looks great smoothed __________________ My carbon clad s2

24-02-2010, 10:02 PM	#23
andy130 PassionFord Post Whore!! Garage is empty, add now Trader Score: (2) Join Date: Jun 2008 Location: ireland Posts: 5,148 Rep Power: 9	looks mint mate but copper brake lines look dirty?

24-02-2010, 11:06 PM	#25
muz Wye Valley Hardcore 1988 Ford Escort Trader Score: (0) Join Date: May 2005 Location: Hereford. West Mids Posts: 3,346 Rep Power: 10	It will do everything you need it to do and more mate. __________________ "BRAVERY IS THE CAPACITY TO PERFORM PROPERLY EVEN WHEN SCARED HALF TO DEATH"

25-02-2010, 05:41 PM	#26
terribletaj Wahay!! I've lost my Virginity!! Garage is empty, add now Trader Score: (0) Join Date: Jun 2006 Location: London Posts: 65 Rep Power: 6	Finished work early today so cracked on with the escort. Got the inlet, fuel rail and injectors, cosworth throttle body, all sensors, new dizzy, throttle cable, top pulley set-up fitted. Got most of the loom in too, just need to renew the fuel pump wiring and connect up the power to the ECU and fit the bottom pulley, then we're good to go. Pic of todays progress:

26-02-2010, 10:39 AM	#27
danny_boy699 chatter 4 life Garage is empty, add now Trader Score: (5) Join Date: Sep 2004 Location: northallerton Posts: 2,471 Rep Power: 10	looks good mate keep the updates coming __________________ check out the mk3 zetec turbo build http://passionford.com/forum/restorations-rebuilds-and-projects/182173-mk3-escort-2-litre-zt-28-3-2010-geting-pissed-off-now-still-no-spark.html Member of "The Daytime pf talk bollocks and random shite club #110 www.stocktonautocentre.com

26-02-2010, 12:31 PM	#28
cossiejsy PassionFord Post Whore!! Garage is empty, add now Trader Score: (0) Join Date: Feb 2005 Location: St Helier,Jersey Posts: 7,589 Rep Power: 15	looking very nice __________________ Dont like my drivin then stop watchin me Jersey Rs Owners Club member of the daytime pf talk bollocks and random shite club #65

26-02-2010, 05:01 PM	#29
Zetec_mk4_XR3i Advanced PassionFord User Garage is empty, add now Trader Score: (0) Join Date: Sep 2003 Location: Sunny Dunfermline, Fife Posts: 2,397 Rep Power: 11	work of art mate - well done __________________ my mk4 Escort Bonus, ST170 + throttle bodies in OAP gold 193 bhp & 13.7 1/4 mile at 102mph http://passionford.com/forum/picture...16v-bonus.html

13-03-2010, 04:12 PM	#30
terribletaj Wahay!! I've lost my Virginity!! Garage is empty, add now Trader Score: (0) Join Date: Jun 2006 Location: London Posts: 65 Rep Power: 6	Little update, It's done! Had a few teething problems but with some help from Jano she's now running sweet, just need to get some miles on her then can turn up the boost! Here's some pics:

13-03-2010, 04:48 PM	#31
muz Wye Valley Hardcore 1988 Ford Escort Trader Score: (0) Join Date: May 2005 Location: Hereford. West Mids Posts: 3,346 Rep Power: 10	That really does look cracking mate! Hats off to you. Love it! __________________ "BRAVERY IS THE CAPACITY TO PERFORM PROPERLY EVEN WHEN SCARED HALF TO DEATH"

23-05-2010, 05:56 PM	#32
terribletaj Wahay!! I've lost my Virginity!! Garage is empty, add now Trader Score: (0) Join Date: Jun 2006 Location: London Posts: 65 Rep Power: 6	Little update, Got fedup of the constant rubbing and poor handling with the escort cossie wheels, so decided to changed them for something better sized. Went with some 7x16 compomotive 6 spoke MOs: Drives so much better now, can put my foot down without it weaving all over the road now. Also the headgasket and pistons rings are dead so brought another CVH, this one will be fully forged with a decent head so should make some decent power! Will update when work starts on it.

23-05-2010, 06:13 PM	#33
smitsturbo PassionFord Post Whore!! Garage is empty, add now Trader Score: (0) Join Date: Oct 2005 Location: aberdeenshire Posts: 7,246 Rep Power: 14	looks nice mate well done __________________ www.sitechracing.co.uk

23-05-2010, 09:48 PM	#34
harvcore Too many posts.. I need a life!! Garage is empty, add now Trader Score: (8) Join Date: Jun 2005 Location: aberdeenshire Posts: 665 Rep Power: 7	ace

23-05-2010, 10:30 PM	#35
oibren85 If in Doubt Flat Out... Garage is empty, add now Trader Score: (0) Join Date: Nov 2006 Location: Earith, Cambridgeshire Posts: 698 Rep Power: 6	Love it, really nicely done, not a super fan of the wheels. But then again think they look amazing on RS7! top work.

23-05-2010, 10:44 PM	#36
Twins 15K+ Super Poster!! Garage is empty, add now Trader Score: (14) Join Date: Sep 2004 Location: ESSEX Posts: 15,591 Rep Power: 23	Looks great on them wheels ,would be tepmted to get a dmb sticker set down the sides if it were mine __________________ My carbon clad s2

25-05-2010, 10:23 AM	#38
jonny s2 PassionFord Post Whore!! Garage is empty, add now Trader Score: (12) Join Date: Apr 2009 Location: west coastcustoms Posts: 4,180 Rep Power: 7	awesome craftmanship mate __________________ power is nothing without control

25-05-2010, 11:02 AM	#39
H7 CYA I've found that life I needed.. It's HERE!! Garage is empty, add now Trader Score: (3) Join Date: Jan 2009 Location: uk Posts: 1,355 Rep Power: 5	That really does look good, loving the new wheels too! Top work mate.

25-05-2010, 11:18 AM	#40
stembo21 Advanced PassionFord User Garage is empty, add now Trader Score: (1) Join Date: Dec 2006 Location: Hull Posts: 2,019 Rep Power: 8	nice car mate __________________ my escort estate project http://passionford.com/forum/restora...5-09-11-a.html

25-05-2010, 11:18 AM
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