Hi Guys,

Thought i'd share with you my Escort Bonus side project that i'm doing along side my black ERST.
I travelled ALL the way to Lincoln to collect it from my good friend LincolnDanny so you may recognise it!

The plan was to run the car as a standard 1.3 HCS to the ground, and then switch over to run full RST mechanicals when/if the engine went bang.
Well a couple of weeks ago it went bang, with a plume of white smoke out the back a bent rod and a hole in the block
And yes it was my fault, ran her low on oil knocking commenced and just ran her until she gave up, very naughty i know, but it's only a shitty HCS.

Here's what she looked like when i first picked her up from Danny's


Then my mate Ash very kindly gave me some free G-max springs and shocks Cheers fella




Then i picked up a cheap set of Superleggeras from the Bay


Just after this the engine went pop so i started buftying bits up for the turbo rebuild.
First item for treatment was the throttle body (ive lost my before pics so i'll add these when i find them!)




Then the metering unit
Stole this pic from Danny's thread, but mine was just as bad as this:

All of the bits i needed for the metering unit rebuild are here


And the after pics:








Inlet manifold before


And after, bolted to a fully rebuilt skimmed head, cheers to Paul 66 turbo for the Bailey breather.



Rocker cover needs either highly polishing or painting as does the breather. And yes that dump valve will be binned as soon as i can get a new top hose or a blankin plug.
I have also replaced all of the injector seals and plastic sleaves for brand new items:




Alternator






I've also bought this GRS from Scorted on here for a bargain Ł150


That's all for now folks, got a load of parts on order to rebuild the bottom end with, so i'll update soon!

 

great stuff pal!
i think im needing another base model

 

looking good mate.

 

good luck on the project mate

 

i love bonus projects,
keep the updates coming

 

Looks great, and love Base models.
Gonna watch this thread, gonna do the same with my Mk4 aswell

 

looking sweet mate, where did you get the new injector sleaves and seals from

 

nice bonus you got there mate,cant wait to see the progress pics engines looking good

 

looks very good so far. keep it up mate.

wish i had a buddy that gave out free suspension lol

 

Cheers for all of the great comments!
The injector sleaves were from an FAI headgasket pack for an xr3i i got from halfords for Ł2.50! 90% of the gaskets are the same for the CVH turbo lump, I'll try and find the part number so you can enquire if you like?

Cheers
James

 

Hoorah, finally a thread on Bert! Metering unit looks mint as! First weekend of August i believe Ford Fair is....

 

Great thread ,love a base model

 

Bonus's rule! Keep up the good work mate, hope your keeping bonus spec bumpers etc?

 

Brian

 

yes please mate that would be great

cheers

 

Halfords part code is 112334
and FAI code is HS191/TDJ441

 

Good work there pal
what you painting the stuff up with?

 

 

Cheers fella.
Using Stratos silver paint, halfords high temp alluminium paint for the head, plastikote Gold and Frost restoration Detail Gray

 

Cheers bud!
Thanks for sorting those parts out for me! can't find any of the other bits any cheaper, was just those rings that were a bit pricey, really appreciate it!
First week of August you say? i know i'm slow but i'm not that bad

 

nice project that is m8 idea for a nice stealth weapon

 

i still have a few bits kicking about if you need any turbo or bonus parts

 

coming on well

 

Cheers mate, what bits do you have kicking around?

 

Well i've been collecting some new parts for the Bonus, just need to get them fitted now!

New Bosch Fuel pump:


Brand new Genuine Ford headgasket and locating dowels


New turbo oil hose


Gen ford sump gasket and oil cooler seal


Most of the bits i need to rebuild the bottom end with


Mk6 Escort clutch pedal, quadrant and rubber


NOS genuine Ford Gearbox mount bushes


Exhaust clamps


New Ford Flywheel bolts


Temp sensor


Collins actuator


And NOS throttle cable for a tenner


The few parts i need now are:
0.5O/S pistons & block boring to suit
Piston Rings to suit
AP clutch
New T3 turbo

Then i'm done!

Another update on Sunday hopefully!

Cheers
James

 

will be loadsa fun when its running pal

 

good stuff mate, would be ace to get a bonus feature in one of the mags eh!

Lookin forward to gettin them altogether at Ford Fair

 

ive got loads of bits left like, rst early spoiler in grey, ecu brackets, loads of plastic trims,etc plus loads i cant think of at the minute

 

got to love a bonus !!!!


beef

 

 

So it's a Sunday and time for an update.
Been a busy week or two and had a big push on the Bonus this weekend to get her a step closer to being done.

Last weekend i popped over to Derby to pick up a new bottom end up from Mart RS as mine needs boring out (which means new pistons) and also has over sized Main journals which means i need funny sized bearings that are a royal pain to get hold of so a new bottom end was the easy option plus this is an EFI block with a CPS hole so if i ever want to go EFI theres less messing about.
Anyway I eventually got to Marts and the engine looked good and turned over smoothly and was told there was no knocks smoking or bangs when it was on the road so gave Mart the monies and got it home.
Soon as i got in i stripped her down which revealed 1.0 mm O/S pistons and 4 bent conrods, gutted





Spoke to Mart and he said he would sort me out a replacement set of rods - cheers Mart, top bloke even met us at the train station when i got mega lost

Luckily however there's no wear on the bores or the piston skirts
So onto this weekend:

First up got my rad painted:


Took the exhaust and head off the Bonus:




Would of got the bottom end out too but this happened to my ball joint separator, bloody cheapo Laser gear


So gave that in as a bad job and continued buftying,

Finished off painting my gearbox




Honed & degreased the block, and painted it up



Painted my cam cover & breather and quickly fitted my Dizzy.


Finished refurbing my fuel lines from the metering unit to the head:





Finished the weekend off by starting to paint my exhaust manifold


And i've also stripped the clutch/brake pedal assembly down for the mk6 pedal conversion, which i just need to rebuild so i'll update with pics as soon as i've done that (after me Tea!)

Cheers
James

 

great work so far jimmy!
shame about the rods MARTS, normally ok guy really helpfull chap

 

lookks good :P the gearbox came up a treat.

 

Great progress

 

Looking Spanking mate :thumb:

 

great mate good project

 

did you get the rods sorted??
if not i got a decent set you can have

 

Come on mate we need some more updates! Got a set of rods here if you need them!!! Wiring loom is al done too!!!!

3 Months till Ford Fair......

 

Wow this is gonna be mint when its done.

 

looking very good mate