Project Escort - mk6 RST.
 

*beware,, LONG thread - its not quite up to par with what some of you guys do but its pushing my own personal limits*

Well my mk5 cab project never really got off the ground due to lack of cash, tools and space to work in so it was pretty much abandoned.

I then picked up a T plate mk6, 5 door escort finesse with a snapped timing belt and therefore a buggered 1.6 zetec engine. at the time my 2l fiesta SI was falling apart with rust so i decided to pull out the engine and fit it to the escort which i then used for several months and tbh was a great motor. 2l zetec, 4-2-1 manifold, decat, stainless exhaust, rs2k brakes, wingback seats and with steel wheels and bumper cracks on view - good for catching out the boy racers!

anyhoo the tax/mot ran out and i felt like a project so i decided to use this.

plan was to do something a little different but do everything myself. im not bad when it comes to fitting or removing bits, but bodywork and wiring i wasnt too hot at, but i figured it give it a go and see what i could do, doings the best way of learning eh? - plus i had loads of decent parts kicking about from cars i had bought and stripped!


planned spec list at the time;

S2 Escort RS Turbo sideskirts and arches
standard front bumper with undecided splitter
standard rear bumper with spats
duel exit exhaust
morettes
saph bonnet vents
smooth rear doors (on poppers)

wheels/suspension/brakes
front upper and lower strut brace
rear strut brace
polybushed as much as possible
lowered approx 60mm on avo adjustable coilovers
16" sigma alloys (azev copies) (possibly refurbed in black)
300mm pumaspeed front brakes
270mm rear disk brakes

interior
RS2000 (mk6) full interior
custom dashboard.
a few gauges.
and a few little personalised goodies.

Engine
s2 RS Turbo engine (MFI)

ive almost kept to that word for word! heres the piccies and info
(copied from other sites, so timeline is pretty much as you read it)

with the 2l fitted.
https://img65.imageshack.us/img65/66...2007021ks9.jpg
https://img129.imageshack.us/img129/...2007018gs4.jpg
fez si seats.
https://img508.imageshack.us/img508/...2007023bc0.jpg
RS2k brakes JUST clearing the steelies.
https://img252.imageshack.us/img252/...2007022qa8.jpg

then tax/mot ran out and i started stripping it.


my 2 2l zetec engines
https://img254.imageshack.us/img254/...bcd0018tf2.jpg
https://i252.photobucket.com/albums/...8_02020041.jpg

a few escort parts...
https://img20.imageshack.us/img20/8756/abcd0019lr3.jpg

the central heating
https://img352.imageshack.us/img352/37/abcd0020pk1.jpg
https://i252.photobucket.com/albums/...8_02020045.jpg

suspension & wishbones stripped out.
https://img527.imageshack.us/img527/...bcd0003ic8.jpg

interior stripped out
https://i252.photobucket.com/albums/...8_02020051.jpg
https://i252.photobucket.com/albums/...8_02020052.jpg
https://i252.photobucket.com/albums/...8_02020053.jpg

the turbo engine still in the cab
https://i252.photobucket.com/albums/...8_02020043.jpg

loom stripped back off
https://i252.photobucket.com/albums/...8_02020055.jpg
https://i252.photobucket.com/albums/...8_02020058.jpg

turbo engine out
https://i252.photobucket.com/albums/...8_02020066.jpg
https://i252.photobucket.com/albums/...8_02020068.jpg
https://img168.imageshack.us/img168/...bcd0004bu4.jpg
https://img120.imageshack.us/img120/...bcd0002yv8.jpg

no prizes for guessing who was doing all the work eh :P
https://i252.photobucket.com/albums/...8_02020067.jpg

**********************************************


so heres an update for what i have done.

cleaned up the block and fitted new water pump
https://i252.photobucket.com/albums/...ABCD0006-1.jpg

sealed the inside of the car (escorts are prone to leaks and wet floors - just to stop if rotting from inside out, plus it gave me a chance to check the floor)

https://i252.photobucket.com/albums/...r/ABCD0017.jpg
https://i252.photobucket.com/albums/...ABCD0007-1.jpg

started on my custom centre console

from an escort and granada consoles

https://i252.photobucket.com/albums/...r/ABCD0018.jpg

to a crossbreed

https://i252.photobucket.com/albums/...r/ABCD0004.jpg

pic of the s2 RST skirts taped up to check how they fit.

https://i252.photobucket.com/albums/...r/ABCD0012.jpg

then bought some vents for my bonnet

https://i10.photobucket.com/albums/a...ade/c64c_1.jpg

bit more stripping

https://i252.photobucket.com/albums/...r/ABCD0014.jpg
https://i252.photobucket.com/albums/...ABCD0017-1.jpg

then used the spray gun and a can of schutz to finish the inside.

https://i252.photobucket.com/albums/...ABCD0019-1.jpg


decided what i was doing with my dashboard
https://i252.photobucket.com/albums/...sar/dash-1.jpg

now got that pretty much in, did it so that i can take the screen out if i want too. also fitted a twin gauge pod to the top.

centre console almost done, just gonna do a wee bit more then cover it with black material.

https://i252.photobucket.com/albums/...ABCD0004-1.jpg
https://i252.photobucket.com/albums/...ABCD0003-1.jpg

fitted the front arches, not a bad fit tbh. need a bit of trimming though, gonna extend the arch line onto the bumper a bit and smooth the skirts in to make it look like theyre meant to be there. the back arches will take a bit more work with it being a 5 door, need to think about how exactly to fit them.

https://i252.photobucket.com/albums/...ABCD0020-1.jpg
https://i252.photobucket.com/albums/...ABCD0002-1.jpg
https://i252.photobucket.com/albums/...ABCD0001-2.jpg

i did have the engine for sale until a mate offered me a car for it. he took the engine and then fucked his own car so wanted to keep it to run about in for a while. he ripped the cunt a bit so i just took the engine back and told him to keep the car so its going back into the motor again. well once i get the crank sprocket i need (hopefully sunday!!)

really gonna try get this finished in the next few weeks. hate not having my own motor!

**************************************

wee bit more done tonight, and FINALLY got the crank sprocket i needed so the engine will hopefully going in 2moro!

back arches;

arch on and bit cut away so that door can open
https://i252.photobucket.com/albums/...ABCD0017-2.jpg
https://i252.photobucket.com/albums/...ABCD0018-3.jpg

the rest of the arch bonded onto the door;
https://i252.photobucket.com/albums/...ABCD0006-2.jpg

door closed;
https://i252.photobucket.com/albums/...ABCD0009-3.jpg

looks rough as fuck atm but will look better 2moro when its dried and i've fibreglassed it. should also get the 2 pieces to sit a bit closer together.

made a start on sorting out the loom. fuck me it aint for the faint of heart.
https://i252.photobucket.com/albums/...ABCD0007-3.jpg

engine bay (with air con and zetec loom out)
https://i252.photobucket.com/albums/...ABCD0008-3.jpg

********************************
polybushing started..
https://i252.photobucket.com/albums/...ABCD0005-1.jpg

the difference between the cvh and zetec PS connections.
https://i252.photobucket.com/albums/...ABCD0004-2.jpg

a bit more done to mould the arch in, need a little bit more work but its getting there!!
https://i252.photobucket.com/albums/...ABCD0017-3.jpg
https://i252.photobucket.com/albums/...ABCD0018-4.jpg
https://i252.photobucket.com/albums/...ABCD0019-5.jpg

in the last pic where it looks as if theres a massive gap theres not. the white is adhesive (sp?). theres about a 4mm gap all the way round that'll i'll hopefully sort next time im at it.

**************

back arch still needs a tad more work, managed to get a spare set of skirts and extend the set i had so that they'd fit. the s2 skirts are about 4 inches too small for the mk6. doesnt look too bad imo :)

https://i252.photobucket.com/albums/...ABCD0007-4.jpg
https://i252.photobucket.com/albums/...ABCD0008-4.jpg
https://i252.photobucket.com/albums/...ABCD0009-4.jpg
https://i252.photobucket.com/albums/...ABCD0011-2.jpg
https://i252.photobucket.com/albums/...ABCD0012-4.jpg
*******************************

fair bit more done tonight.
zetec radiator out, RST radiator in, welded in brackets to hold it in and fited my intercooler roughly where it'll go. started clearing up the wires a bit ready to be tucked away.

welded up my exhaust, then had to grind off the towing eye and weld in a hanger to fit it. car sounds fucking awesome now!
https://i252.photobucket.com/albums/...3052008986.jpg

it looks to be hanging a little low on the right in that pic which i never noticed so will sort that mext time im down.

started building the front end back up, new wishbones, track rod ends and ARB links, fitted front suspension too. once i finish my arches i'll get the arch liners cleaned up and back in. also got my remote start kit through today which i'll fit during the week, after all the wiring of the engine i feel a bit easier in attempting it myself.

next on the cards is to order new brake hoses and find a bush for my rear beam so i can get it fitted again, then finish the skirts and arches. after that i'll be welding up my rear door handles and fitting poppers and fitting the bumpers.

then its just interior to go!

**********************************************

wee bit more 2nite.

sadly the exhaust tone isnt as noticeable as i had hoped but i'll decide when i get her on the road ifi want to tinker with the exhaust a tad. still need to adjust the o/s pipe to sit up and in a bit which i'll hopefully get done 2moro.

fitted the back bumper for the time being, started smoothing in the spats, added the arch round onto the rear bumper and did a bit more work on the skirts. they still need a load of work to get them smooth but its getting there slowly. body work is something ive never did alot of so this is all new to me (as you can see from the mess i make and then have to spend hours cleaning it up - like the amount of evostick ive got the arches bonded on with lol!)

piccies..

https://i252.photobucket.com/albums/...7052008995.jpg
https://i252.photobucket.com/albums/...7052008993.jpg

its starting to look like a car again!

as per, comments welcome :)

**********************************

wee bit more done today.

from
https://i252.photobucket.com/albums/...7052008995.jpg

to

https://i252.photobucket.com/albums/...9052008996.jpg
https://i252.photobucket.com/albums/...9052008997.jpg

it still needs a bit more work to smooth it in. did a bit more work to the skirt/arches you can see, and fitted the skirt at the other end.

tbh im getting pissed off again, i fucking hate having to sand down filler and use it tiny bits at a time to get something spot on. but as i said i want to do most of it myself so i'll keep on.

**************************************

all niter last nite..

old bumper trial fitted so i could see roughly where the cooler will sit. will need to be adjusted a bit to straighten it and so i can still get a fan in though
https://i252.photobucket.com/albums/...0620081153.jpg

arches brought over onto the front bumper, still needs perfecting and alot of smoothing in and sanding down but its taking shape!

https://i252.photobucket.com/albums/...0620081154.jpg
https://i252.photobucket.com/albums/...0620081156.jpg

**********************************

right, ive got the finger out a bit now and started work on the motor again.

decided to flushthe bootlid to go with my smoother look, but the one thing i dont normally like about it is how the number plate always looks like an afterthought and is just screwed to the bumper, so..

i took the recess from a proton and moulded it into my bumper, still needs a wee bit of smoothing but doesnt look too bad imo, also did a bit more work smoothing in the spats and in sorting the flat spots on the skirts/arches. definately decided though.. i fucking hate sanding and will avoid it at all costs in future!

Started to build up my hubs again, so hubs, shafts, ARB links, TRE's, and new brake pipes all fitted just waiting for a 12mm drill bit 2moro so i can fit my 300mm stoppers, then its onto polybushing my rear beam and refitting!

piccies..

https://i252.photobucket.com/albums/...0720081197.jpg
https://i252.photobucket.com/albums/...0720081196.jpg

i still need door poppers like what was posted on here a few posts back. ive emailed that place 3 times and had no reply so i dont fancy sending them money, any other ideas on where to get them?

******************************

just got home from the yard, been down there since 1pm yesterday lol and got a load done.

got everything bolted back up and sorted my fueling issue, no more backfiring! but now she wont idle lol...

got most of the drivers side skirt/arch finished - just needs a few finishing touches and its done, finished the door handle too so one side of the car is almost done bodywork wise.

plate welded my boot and smoothed it in, still not entirely happy with it but primered it and stuck bumper on to see how it looked.

then got my rear beam and suspension bolted back up, did the front brakes the other day.

so she's defo taking shape, and its something a little different from the usual 'GTi/rs2k' rep!!


the bumpers still need a bit of work, and my sander broke so im gonna have to go buy another un. a big thanks to Craig for coming through and giving me a hand, i would never have got as much done without him.

piccies..

from
https://i252.photobucket.com/albums/...r/Image062.jpg

to

https://i252.photobucket.com/albums/...r/Image063.jpg

to

https://i252.photobucket.com/albums/...r/Image065.jpg
https://i252.photobucket.com/albums/...r/Image064.jpg

***********************

thats where im up to just now, hoping to have it done for Ford Fair, tbh theres not that much to do but gona need to work like fcuk to make sure its there! Up till now i reckon the car and everything i have for it have cost me about £800, but theres been a fair few hours put in now!

opinions welcome!

top work mate as said on the other site.

nice work, thats some lock up you have there mate

looking very good i will be keeping an eye on this

lots if hard work gone into this pal, keep it up :top:

It's shaping up well.

Only one thing I don't like is the de-handled rear doors. Always looks odd and out of balance to me.

That small gripe aside, top-notch

cheers guys,

i love the smooth rear handles mike. it brings a bit of attention to the car because you have to look twice to see whats missing.

everything will be relatively 'smooth' but i would rather be able to get in/out of the drivers seat hence keeping the front locks/handles.

Looks a familiar project lol.

Coming along, Ford Fairs looming mind :P

right update, gonna get a few mixed opinions here i reckon.

anyhoo, i dunno if ive made a big mistake by doing what ive done.. ive fitted 1 mk5 rear light to the car, reason for one is im experimenting - which i almost wish i hadnt done.

bad thing is that ive done it right, and actually cut out the mk6 light panel and welded in the mk5 one. the light itself looks awesome and IMO really tidys up the back end, but i didnt really think it through fully and realised a bit late how square the lights were and how they sit in behind the bootlid.

the only way i seen to try sort it was to cut the right bit from the mk5 cab bootlid i had and weld it in so that i had the right crease, but to even get that right i had to use a mallet... ALOT.

anyhoo piccies..
garage cleaned..
https://i252.photobucket.com/albums/...r/Image080.jpg

mk5 panels
https://i252.photobucket.com/albums/...r/Image081.jpg

mk6 light panel
https://i252.photobucket.com/albums/...r/Image082.jpg

gone..
https://i252.photobucket.com/albums/...r/Image084.jpg
https://i252.photobucket.com/albums/...r/Image083.jpg

mk5 light panel welded in and light in place (looks awesome here IMO)
https://i252.photobucket.com/albums/...r/Image085.jpg

then i fitted the bumper and shut the bootlid and noticed the problem, heres how it says with the way i tried to solve it.. (note bootlid still needs major sanding down, primer was just on to make it the one colour)
https://i252.photobucket.com/albums/...r/Image092.jpg
https://i252.photobucket.com/albums/...r/Image093.jpg
https://i252.photobucket.com/albums/...r/Image094.jpg

as you can see if i keep it i'll need to weld a panel in to bring out the bottom of the light to sit in line with the bootlid. but im really not sure.

3 choices IMO;
1)keep it as it as and fit the other mk5 light the same way, weld the panels and be happy with it.
2) buy a mk6 and cut the light panel out and put my car back to a mk6 rear end
3) fit a mk5 tailgate.

i need some serious opinions on this because im genuinely stuck at what to do. ive now decided i did quite like the mk6 back end as i had it and shouldnt have touched it, but i also really like the mk5 lights.

anyone got any pics of a mk5 lid on a mk6?

im gutted that ive set myself back a right few days work, its making ford fair mega tight time wise. but im still hopeful.


apart from that i dropped the car down onto its wheels to see how it looks, the skirts/arches just need 1 tiny wee bit more tidying up then i can finish the bumper (and wind the suspension right fucking down!)
https://i252.photobucket.com/albums/...r/Image088.jpg
https://i252.photobucket.com/albums/...r/Image090.jpg
https://i252.photobucket.com/albums/...r/Image091.jpg

rest of the car, erm..
incar PC is finished and running, got meself a new screen too just need to mould it inot my dash.
interior will be done this weekend when the outside of the car is finished, then its just a matter of double checking ive done and fitting my gauges and doing all the other wee shitey bits ive avoided until now - then finally MOT/tax/setup & tracking and paint!


oh aye, new engine being picked up on Saturday with a healthy bit more power than mine was!
so fingers crossed, saturday night i can get a shot of her up and down the street!


as per, comments and honest opinions welcome.

good work man, i decided to let my 1st post be here since it is a very buitiful project your working on, glad to know everythink is going well

Allot of work their !!! but its comin on nicely! when's ford fair again? August 26th or somethin?

Oh, u got any 2.0 zetec std rods lying about? :D

the 3rd mate, a fortnight!!

i dont mate but theres a fella on another forum im on selling a set.

http://www.escortevolution.co.uk/for...pic=106237&hl=

thanks mate ;)

cheers Mate, bit pricey though im not in a great rush atm anyway!

still got the rest of the car to build :cry:

keep up the good work :DD:

gave up on the mk5 idea, too much work and not enough time.


so i bought this last night, and it stayed like this until 2day..
https://i252.photobucket.com/albums/...r/Image101.jpg

an hour later
https://i252.photobucket.com/albums/...r/Image106.jpg

my new rear end.
https://i252.photobucket.com/albums/...r/Image107.jpg

a few bits and pieces so i can start putting her back together.
https://i252.photobucket.com/albums/...r/Image108.jpg

hopefully get my light panel welded back in tonight, and if possible my new bootlid back on and plated.

wedding venues in herts and essex nice arab girl
 

Edited

^^^ what the fcuk ?

any more updates on this??

its not changed much, will get some piccys up later on.

You need to crack on then looks like your well on the way to having a pretty unique car there keep it up

crack on mate wanna see it finished

liking the arches on there mate, dont see many nicely modded/different 5 door escorts. Its looking good :grin:

Good luck with the project