Escort RST S2 RWD Cosworth, update 8/12/16
19-02-2012, 07:32 PM
#85
.
I've managed to get a bit done over the last few weeks, 1st off all the floor from the back of the door forward is all now finished including the inner front arches, sill and the section around the back end of the tunnel.
Few pics
And after extending the hight of the spit i got the car upside down, fitted some out rigger legs to support it and keep it level, and then started mocking the rear axle up so i can sort out the 2 forward mounting points, hoping to have everything lined and measured up this week so i can weld in the mounts.
Picked this up from a local scrappy for Ł30
And picked this one up 3 weeks later from the same scrappy for another Ł30
The front is valance is designed for the Orion 16i Ghia bumper, but after a bit of a trim it fits the 80 spec bumper
I want as much air going into the front of the car so desided to modify the bumper a bit, I'm not 100% sure if i'm going to use the valance's yet or not so i've modded them so i can use them with or without it. Now i hate fully cut out bumpers so a few minor mods went from this
to this
and a bit more trimming to this
Subtle i think
Fitted it to the car for a look
Added the valance
against the flared arch
and the bumpers
Thats all for now, more soon.
Ginger
.
I've managed to get a bit done over the last few weeks, 1st off all the floor from the back of the door forward is all now finished including the inner front arches, sill and the section around the back end of the tunnel.
Few pics
And after extending the hight of the spit i got the car upside down, fitted some out rigger legs to support it and keep it level, and then started mocking the rear axle up so i can sort out the 2 forward mounting points, hoping to have everything lined and measured up this week so i can weld in the mounts.
Picked this up from a local scrappy for Ł30
And picked this one up 3 weeks later from the same scrappy for another Ł30
The front is valance is designed for the Orion 16i Ghia bumper, but after a bit of a trim it fits the 80 spec bumper
I want as much air going into the front of the car so desided to modify the bumper a bit, I'm not 100% sure if i'm going to use the valance's yet or not so i've modded them so i can use them with or without it. Now i hate fully cut out bumpers so a few minor mods went from this
to this
and a bit more trimming to this
Subtle i think
Fitted it to the car for a look
Added the valance
against the flared arch
and the bumpers
Thats all for now, more soon.
Ginger
.
07-04-2012, 08:35 AM
#90
.
Well i've been really busy in work (again) but i have managed to get the car to a rolling shell There's a few pics i forgot to take but will get them next week.
Anyway, pics do the talking, SO
Templates for axle mount
Axle mounts, These have done like this to make them as strong as possible and have been boxed over with 2mm plate to make it look neater. (
I had to build up the cossie back axle, so the rear stub axles got a clean up
front wheel difference from flared and nonflared
Had a bit of a cock up yesterday as i hadn't noticed i was almost out of welding gas, and being Good Friday BOC was closed, So i thought i'd get the car out the garage so i could have a good clean up and get some pics
Random order
Looks good me thinks
Got load of tidying up things to be doing, so gonna get the car back on the spit on Monday and hopfully i'll get some time to get the 2nd front arch flared and the two rears.
Thanks for looking.
Ginger
.
Well i've been really busy in work (again) but i have managed to get the car to a rolling shell
There's a few pics i forgot to take but will get them next week.Anyway, pics do the talking, SO
Templates for axle mount
Axle mounts, These have done like this to make them as strong as possible and have been boxed over with 2mm plate to make it look neater. (
I had to build up the cossie back axle, so the rear stub axles got a clean up
front wheel difference from flared and nonflared
Had a bit of a cock up yesterday as i hadn't noticed i was almost out of welding gas, and being Good Friday BOC was closed, So i thought i'd get the car out the garage so i could have a good clean up and get some pics
Random order
Looks good me thinks
Got load of tidying up things to be doing, so gonna get the car back on the spit on Monday and hopfully i'll get some time to get the 2nd front arch flared and the two rears.
Thanks for looking.
Ginger
.
but looks good so far 
13-05-2012, 10:48 PM
#98
.
Bit of an update, i had a few days off last week so i cracked on, Managed to get the bulkhead finished and get the wiper, fuse box and heaters all in and fitted, I had to cut the panel into 3 pieces and replace the section where the wiper motor would fit in a Sierra as it was to high.
Some pics of the finished item.
After decideing that i didn't want to go the S1 kit route i flared the one of the front arches, ths time it was the rears turn, So i manged to flare one by 17mm, Not much i know but it's enough. I had to repair and flare the inner arch aswell so that the new arch had some thing to weld to.
And started on the drivers side arch.
Thats it for now, hope you all like the progress
Ginger
.
Bit of an update, i had a few days off last week so i cracked on, Managed to get the bulkhead finished and get the wiper, fuse box and heaters all in and fitted, I had to cut the panel into 3 pieces and replace the section where the wiper motor would fit in a Sierra as it was to high.
Some pics of the finished item.
After decideing that i didn't want to go the S1 kit route i flared the one of the front arches, ths time it was the rears turn, So i manged to flare one by 17mm, Not much i know but it's enough. I had to repair and flare the inner arch aswell so that the new arch had some thing to weld to.
And started on the drivers side arch.
Thats it for now, hope you all like the progress
Ginger
.
10-06-2012, 09:20 PM
#103
.
Small up date,
Managed to get the drives rear arch finished today. It's getting there
Before new inner lip was fitted
inner lip done
Arch all welded up and red oxided inside and out
Also managed to get a pair rear disc dust guards nice and cheap of flea bay, there 275mm version which are smaller then my originals, but they fit so i'm happy
Been looking at wheels aswell, as I have 4 sets in the garage, 2 x 15's and 2 x 16's with different widths and offsets, plus different J's 6.5 & 7 in both the 15 & 16's. I'm looking good for a 16" 7j-37 offset with 205/45/16's might ever be able to squezze a 215/40/16 on the rear which i'll be well impressed with.
Got a set of standard Escort cossie rims to try soon aswell, gonna try fittng them without the disc fitted to make them a 32 offset so i can see if 8j will fit without touching the swing arms.
It's getting there slowly,
Cheers,
Ginger
.
Small up date,
Managed to get the drives rear arch finished today. It's getting there
Before new inner lip was fitted
inner lip done
Arch all welded up and red oxided inside and out
Also managed to get a pair rear disc dust guards nice and cheap of flea bay, there 275mm version which are smaller then my originals, but they fit so i'm happy
Been looking at wheels aswell, as I have 4 sets in the garage, 2 x 15's and 2 x 16's with different widths and offsets, plus different J's 6.5 & 7 in both the 15 & 16's. I'm looking good for a 16" 7j-37 offset with 205/45/16's might ever be able to squezze a 215/40/16 on the rear which i'll be well impressed with.
Got a set of standard Escort cossie rims to try soon aswell, gonna try fittng them without the disc fitted to make them a 32 offset so i can see if 8j will fit without touching the swing arms.
It's getting there slowly,
Cheers,
Ginger
.
16-07-2012, 09:18 PM
#107
.
Slow progress report :-(
Been trying out different wheels to check clearance. On an Escort the rear track is wider than the front, but the opposite on a Cossie., so the front arches need to be widened/flared more than the rears.
I managed to borrow a set of Escort cossie wheels and a defo no no, An ET25 is way to low for a 8J, so i managed to borrow a set of 8J 18's ET40 with 205/35/18's. The rears a perfect, at full drope they stick a few mm, but on the floor with 4 of my mates sat in the back and without the inner lip of the arch removed and almost the full tire up in the arch there was a good 5-10mm gap so 8 or 8.5J ET37 - 40 with a 215 tires is looking good at the rear
As for the front's, the same wheel sticks out 12mm past the 10mm flared arch, so i got a set of front arches of another car and will be widening the front to at least 25mm from standard (if i can), plus i'm gonna fit adjustable top mounts and TCA's to narrow the track about 5mm both sides.
Any way a few pics. ( please ignore the shitty wheels, shocking i know )
Spare arches
Also since fitting the rear crossmember/diff hanger mounting point it became obvious that i'd mounted it about 10mm to low in the car, So after cutting the centre section back out and temp welding it back in 20mm higher it was a lot better.
So, out came the grinder and the crossmember was completely removed, As was the centere section of the boot floor, the removed floor section is now going to be rasied up to the height of the new crossmember.
The mounting face for the diff hanger is now 20mm higher than it was originally, but i do have a 5mm spacer if it's to high.
New crossmember fabricated out of 100x60x3mm box section and welded back in.
few pics
new diff hanger
And the boot floor
Hoping to get the axle back on this week with the rear end on wheels so i can look at the exhaust with the bumper fitted.
Got to make a minor mod to the rear strut tops as the top cup of the coilover is touching it :-( Nothing dramatic though
And a selection of part's i've been buying
Got a few more bit's on order
More updates sooner, i hope
Ginger
.
Slow progress report :-(
Been trying out different wheels to check clearance. On an Escort the rear track is wider than the front, but the opposite on a Cossie., so the front arches need to be widened/flared more than the rears.
I managed to borrow a set of Escort cossie wheels and a defo no no, An ET25 is way to low for a 8J, so i managed to borrow a set of 8J 18's ET40 with 205/35/18's. The rears a perfect, at full drope they stick a few mm, but on the floor with 4 of my mates sat in the back and without the inner lip of the arch removed and almost the full tire up in the arch there was a good 5-10mm gap
so 8 or 8.5J ET37 - 40 with a 215 tires is looking good at the rear As for the front's, the same wheel sticks out 12mm past the 10mm flared arch, so i got a set of front arches of another car and will be widening the front to at least 25mm from standard (if i can), plus i'm gonna fit adjustable top mounts and TCA's to narrow the track about 5mm both sides.
Any way a few pics. ( please ignore the shitty wheels, shocking i know
)Spare arches
Also since fitting the rear crossmember/diff hanger mounting point it became obvious that i'd mounted it about 10mm to low in the car, So after cutting the centre section back out and temp welding it back in 20mm higher it was a lot better.
So, out came the grinder and the crossmember was completely removed, As was the centere section of the boot floor, the removed floor section is now going to be rasied up to the height of the new crossmember.
The mounting face for the diff hanger is now 20mm higher than it was originally, but i do have a 5mm spacer if it's to high.
New crossmember fabricated out of 100x60x3mm box section and welded back in.
few pics
new diff hanger
And the boot floor
Hoping to get the axle back on this week with the rear end on wheels so i can look at the exhaust with the bumper fitted.
Got to make a minor mod to the rear strut tops as the top cup of the coilover is touching it :-( Nothing dramatic though
And a selection of part's i've been buying
Got a few more bit's on order
More updates sooner, i hope
Ginger
.
30-08-2012, 09:38 AM
#110
.
Bit of an update,
Been a bit slow over the last few weeks but i've had a few days off work so got a load of little "i'll sort that out another day" things finished off, Spent a whole day wire brushing and sand blasting the rear turrets inside and out and a few sections under the boot floor corners and got them in red oxide, Also managed to modify the rear axle hoop that goes over the top of the diff to make it lower, plus i've fabricated a new floor section that goes under the rear bench to cver the big whole i had there.
Some pics
At this point the only fabrication work left is the to flare the front arches even wider and the boot floor panel, The boot floor can't be done until i sort out the exhaust, plus it'll be easier with the big hole there, plus when it is done i can measure uo for a one off fuel tank.
The floor is going to be raised up for more space underneath.
So the only way to sort the exhaust was fit the engine, didn't realise it had been in my parents garage for 7 years
After a good clean (wasn't cleaned before storage)
After moving the car sideways in the garage and fitting the running gear back on it was in
And start fitting the exhaust and manifold
With that all fitted the bonnet was back on to check everything cleared and theres about 25mm above the cam belt an15-20 above the FPR. The only issue i had was the inner skin of the bonnet just touching the strut top mounting discs. I new this anyway so marked up where they touched and got my hole cutters out
and....
problem solved.
gonna get the car up on stands and blocks today and make a start on the exhaust as i'm gonna need to order a bit of pipeing
So the 1st engine fit up is done so i can OFFICALLY say i have an S2 Escort RS Turbo YB Cosworth
Ginger
.
Bit of an update,
Been a bit slow over the last few weeks but i've had a few days off work so got a load of little "i'll sort that out another day" things finished off, Spent a whole day wire brushing and sand blasting the rear turrets inside and out and a few sections under the boot floor corners and got them in red oxide, Also managed to modify the rear axle hoop that goes over the top of the diff to make it lower, plus i've fabricated a new floor section that goes under the rear bench to cver the big whole i had there.
Some pics
At this point the only fabrication work left is the to flare the front arches even wider and the boot floor panel, The boot floor can't be done until i sort out the exhaust, plus it'll be easier with the big hole there, plus when it is done i can measure uo for a one off fuel tank.
The floor is going to be raised up for more space underneath.
So the only way to sort the exhaust was fit the engine, didn't realise it had been in my parents garage for 7 years
After a good clean (wasn't cleaned before storage)
After moving the car sideways in the garage and fitting the running gear back on it was in
And start fitting the exhaust and manifold
With that all fitted the bonnet was back on to check everything cleared and theres about 25mm above the cam belt an15-20 above the FPR. The only issue i had was the inner skin of the bonnet just touching the strut top mounting discs. I new this anyway so marked up where they touched and got my hole cutters out
and....
problem solved.
gonna get the car up on stands and blocks today and make a start on the exhaust as i'm gonna need to order a bit of pipeing
So the 1st engine fit up is done so i can OFFICALLY say i have an S2 Escort RS Turbo YB Cosworth
Ginger
.
06-09-2012, 09:38 PM
#114
.
Bit of an update,
Now with the wheel base and the over all lenght of a Sierra being longer than a Mk4 Escort i need to shorten the exhaust in 2 places, plus the rear silencer is oval being taller than the width, so wouldn't fit under the rear chassis rail, so the pipe work was cut off and turn 90' and welded back on so it's now wider than tall.
And after modifying the hanger on the box and drilling the chassis rail for a new hanger it sit's like this
The other part (the wheel base part) needed a bit of a think as there is a silencer in there, I thought about just removing it but don't want it to load, also looked at getting a 16" x 5" silencer but would be very close to the prop, so to save about Ł50 i decided to cut and shorten the silencer, which was a lot easier than i thought
And the end product
The section that runs under the diff is fucked from hitting the floor so i'm waiting on a metre of 3" tube, should be here tomorrow hopefully so i can get that sort over the weekend.
Also got myself a Burton quick shift from a member on here (many thanks)
Was a bit bored earlier so desided to fit it to see how much it shortens the throw, answer 25mm was 105mm 3rd to 4th, now it's 80mm.
Propshaft before i dropped it off
One shortened and rebalanced prop.
Been debating the rear RS valance so tried it on the car, still not sure :-(
And i tried the rear arch a wheel on for a look
I made a template for a while back for an air blower cover, so now the motor is in i checked it fitted and cleared the back of the engine and cam cover,
Fit's perfect, so i need to decide on aluminium or mild steel, if i make it from steel i can make it myself, it's got to be a 2 piece cover as it's a nightmare to get in and out in one piece.
Cheers for looking, and thanks for all the comments
Ginger
.
Bit of an update,
Now with the wheel base and the over all lenght of a Sierra being longer than a Mk4 Escort i need to shorten the exhaust in 2 places, plus the rear silencer is oval being taller than the width, so wouldn't fit under the rear chassis rail, so the pipe work was cut off and turn 90' and welded back on so it's now wider than tall.
And after modifying the hanger on the box and drilling the chassis rail for a new hanger it sit's like this
The other part (the wheel base part) needed a bit of a think as there is a silencer in there, I thought about just removing it but don't want it to load, also looked at getting a 16" x 5" silencer but would be very close to the prop, so to save about Ł50 i decided to cut and shorten the silencer, which was a lot easier than i thought
And the end product
The section that runs under the diff is fucked from hitting the floor so i'm waiting on a metre of 3" tube, should be here tomorrow hopefully so i can get that sort over the weekend.
Also got myself a Burton quick shift from a member on here (many thanks)
Was a bit bored earlier so desided to fit it to see how much it shortens the throw, answer 25mm
was 105mm 3rd to 4th, now it's 80mm.Propshaft before i dropped it off
One shortened and rebalanced prop.
Been debating the rear RS valance so tried it on the car, still not sure :-(
And i tried the rear arch a wheel on for a look
I made a template for a while back for an air blower cover, so now the motor is in i checked it fitted and cleared the back of the engine and cam cover,
Fit's perfect, so i need to decide on aluminium or mild steel, if i make it from steel i can make it myself, it's got to be a 2 piece cover as it's a nightmare to get in and out in one piece.
Cheers for looking, and thanks for all the comments
Ginger
.
09-09-2012, 08:02 PM
#116
.
Hiya mate, i'm gonna make it out of mild steel and paint it, I just need 2 piece's of steel rolled to form the curved part if you can do that mate, i'm not in a hurry to get it done but if i cut the plates ready and you could roll them for me i'd be grateful
Ginger
.
Hiya mate, i'm gonna make it out of mild steel and paint it, I just need 2 piece's of steel rolled to form the curved part if you can do that mate, i'm not in a hurry to get it done but if i cut the plates ready and you could roll them for me i'd be grateful
Ginger
.
10-09-2012, 12:53 PM
#119
Professional Waffler
.
Hiya mate, i'm gonna make it out of mild steel and paint it, I just need 2 piece's of steel rolled to form the curved part if you can do that mate, i'm not in a hurry to get it done but if i cut the plates ready and you could roll them for me i'd be grateful
Ginger
.
Hiya mate, i'm gonna make it out of mild steel and paint it, I just need 2 piece's of steel rolled to form the curved part if you can do that mate, i'm not in a hurry to get it done but if i cut the plates ready and you could roll them for me i'd be grateful
Ginger
.
11-09-2012, 10:24 AM
#120
.
I'm after some help/advice on a fuel tank/system set up, I'm going to be using the complete Sierra wiring loom front to back to make easier as i'll be running Cosworth clocks, ABS etc, and adding the rear wiper wiring from a hatch back Sierra loom.
I need to sort a tank out which isn't an issue but i need to sort out what fuel level sender/sensor i can use that'll work/operate the the standard Sierra fuel guage. I've looked at a standard unit but the height is about 50mm higher that the deepth of the tank i'm looking to get fabricated.
Can anyone point me in the direction of an aftermarket sender.
Cheers
Ginger
.
I'm after some help/advice on a fuel tank/system set up, I'm going to be using the complete Sierra wiring loom front to back to make easier as i'll be running Cosworth clocks, ABS etc, and adding the rear wiper wiring from a hatch back Sierra loom.
I need to sort a tank out which isn't an issue but i need to sort out what fuel level sender/sensor i can use that'll work/operate the the standard Sierra fuel guage. I've looked at a standard unit but the height is about 50mm higher that the deepth of the tank i'm looking to get fabricated.
Can anyone point me in the direction of an aftermarket sender.
Cheers
Ginger
.
