Dan j

I thought id post up my van project nothing overly special just something that has taken me a age to build up. The van is a w reg shell that was originally a 1.8d with no extras other than pas I then decided it was too slow and was too basic. I have bought the following:
96 Escort tdi engine, box, shafts, hubs , linkage and subframe which is fitted and the fuel and boost have been upped. no cat or egr System as standard
Universal front mount intercooler kit
Ford strut brace
Aftermarket lower strut brace will be modified to clear down pipe
300mm st170 discs and pads along with mk3 mondeo calipers and hoses
Weitec gtn coilovers
Modified rear axle with extra leaf spring each side to stiffen springs further will be getting uprated dampers next
Magnex cat back exhaust needs modding for rear of van
17" focus mp3 alloys with 205/40 tires
Escort mk5 rs2000 bonnet, bumper and headlights
Replica rs accessory side skirts for van
Cosworth style van bumper
Mk6 escort hatch electric mirrors
Electric windows, central locking
fully sound deadened front doors
Escort mk6 dash and trim all flocked black
Series 2 88 spec recaro seats
White dials
Fully under sealed

Couple of pics


Some pics from when i was fitting the engine on the 5.5.11



Only took around an hour to sort, engine crane is a god send, Few pics with the mk5 rs front end thats still not finished cutting the bumper out for the fmic



Still got alot of finishing to do and a paint job but ill get there at some point,I only got to work on it at weekends at i never had a driveway. But I have now moved to a place with a drive so its coming home on tuesday.
comments welcome.

syko2005

Looks good that does

studabear

the multispoke alloys really suit it, are they off a focus esp?

syko2005

They are mp3 alloys off a focus

Dan j

What he said with smaller tires i have to run 5mm spacers because of the offset and how low it is. The alloys actually sat on the coilover bodies

jonny s2

iTrader: (12)

focus rims looks fab

Dan j

17s need a paint refurb another in the list of things to do.
Pic of the flocked dash, roof lining is also black and there is some black cabriolet sun visors

And a rear show of the lowness on 15s

Need some new rear doors as the above are rubbish.

atm

Is it on the road yet dan?

Have you seen the mk5 cab in atlas? There was an mk5 rs2k grill inside it.

Dan j

No mate not on the road yet, its one of them long when i can be bothered projects haha. Not been scrappy hunting for a while now not much i need i don't think, also got a cossie grill for the front, might pop to atlas see if theres owt where buying.

Minirotty

Have you got pictures of how you modified the rear?

Have you done the same as RST/Rizzla's van?

Thanks, Kev.

Dan j

No mate no pics, On my flip i have just welded in some escort mk2 saddle brackets I had to shave them slightly to sit on the beam, here's what i used
http://www.ebay.co.uk/itm/Axle-Rear-...item1c1c6ec85e
I removed the brake compensator on the beam and just remade the brake lines.
I left the original axle brackets on so i could swap back if needed, this has not caused any issues how ever it helps mirror where the new brackets need to go.
Another mod I have done is got another pair of top leaf springs cut them so that they where 1" longer at either end than the lower leaf spring. This stiffens the rear up further and lifts it a little you will also need some longer u bolts.
http://www.ebay.co.uk/itm/Escort-Mk1...item1c1be03d42
This will hold the leaf springs together you also need a longer locating bolt i just got a bolt shaved the head down and it fits perfect. Lastly im buying some uprated shocks to finish off the rear end and i know that 306 shocks fit, a mate of mine has them as says it transforms the ride here's what im getting
http://www.ebay.co.uk/itm/Escort-Mk1...item1c1be03d42
Hope this helps

Minirotty

Thanks for putting so much effort into your reply pal, information appreciated!

Dan j

The van is at my house now so I'll take some pictures so you get what im waffling on about haha.

Dan j

Few updates


Back on with the mk6 front end as I got bored of the mk5 route, some pics of my rear axle mods


What you can see in these pics is an extra leaf spring in the middle, longer U bolts, old spring mount,
I kept the old mounts as it made it easy to line up the new mounts underneath and if ever I had to go back to standard height I could.

I took out the load bias valve, I'm told you can adjust them but mine was seized so I binned it.

And finally while I was under there I under sealed the whole of the van, I have had various plates welded but on the whole the underside was tidy.
I have raised the suspension very simple to do with my coilovers. There is a tiny grub screw that holds the platform in place once unscrewed is easy to raise or lower. You get a C spanner that grips the platform and you screw it up or down, with my coilovers like new I could turn the springs by hand.

The coilovers where wound right down to 75mm by the previous owner and was silly low, end result is the van is 35-40mm lower from standard much better for clearing the mountains ( Speed bumps ). I also sold my 300mm brakes to a mate so I've replaced them with 260mm rs2000 discs and calipers.
I decided to get the van running in a fasion

Tried again


Its only taken 2 years to get to this point, many changes way to many decisions changed so its dragged, but im happy I have heard it run.
Well the van now has fully functioning brakes all round and 85% of the brake lines are now redone in copper piping, also fuel tank is finally fitted. I made a start fitting my intercooler too so I drilled the front panel to mount up the ic.

Sits perfect in the bumper but issues with the supplied pipe work means I need to get creative with some focus tdci parts to get it all to work the way I want, next week its gear linkage and exhaust system final fit.

Thats up to date so far still plenty to do.

gouch1

mk6 front looks better imo

phil barnes

how did you get the brakes to fit