1994 - Ford Escort Cosworth - power steering fluid tank

[jonomisfit]

Rear screen removed
P1060595 by jono_misfit, on Flickr

area cleaned up and tape to protect the paint

P1060596 by jono_misfit, on Flickr

adhesive added, rear screen in, and rivetted on

P1060597 by jono_misfit, on Flickr

rear wing back on

P1060598 by jono_misfit, on Flickr

made the clips for the other bonnet vent

P1060599 by jono_misfit, on Flickr

P1060600 by jono_misfit, on Flickr

P1060601 by jono_misfit, on Flickr

P1060602 by jono_misfit, on Flickr

then put the panel bond on

brick on for weight until the bond sets

P1060603 by jono_misfit, on Flickr

removed and painted the column bracket

primed

P1060604 by jono_misfit, on Flickr

top coat on

P1060605 by jono_misfit, on Flickr

halfed the thickness of the old filler blank

P1060606 by jono_misfit, on Flickr

then did a load of other bits and pieces but didnt take any pics.

[jonomisfit]

After a bit of recovery time from my anual pillgramage to Bloodstock festival I did some work on the escort.

I need to do a cable transit for the bulkhead, but don't want to have to strip the connector to pass through the cables, so another two piece transit. A bit simpler than the other one as it doesnt have anythign like the amount of cables to lean on it.

I tried out some things in cardboard, then start to convert to aluminium

P1060607 by jono_misfit, on Flickr

cut out, trimmed and added a step

P1060608 by jono_misfit, on Flickr

go together like so

P1060609 by jono_misfit, on Flickr

i've put a lip on the back to stiffen it up and ensure it it can push evenly on the gasket

P1060610 by jono_misfit, on Flickr

goes in like so

P1060611 by jono_misfit, on Flickr

gasket still to fit

P1060612 by jono_misfit, on Flickr

This splits in two and the top half lifts out to allow cables & connectors to go through. I don't think I need to wire any more through it, but its there if I need to.

I then connected up my spare battery and started the task of checking the electrics work.

Very helpfully I have lost ALL the notes I made when doing the wiring, all my relay, fuse, connection details. gone. I saw them the other week, but having turned the workshop and house upside down I still cant find them.

Had to start belling things out and trial and error to work things out again.

New notes, and check off lists for the checks I made.

P1060613 by jono_misfit, on Flickr

Main faults so far.. the rear side light and fog lights connections are swapped on the nearside.

I couldnt get the blower fan to run in the car. A quick strip down and direct connect to the batter shows a very lazy motor. replacement motorfans are available.

P1060614 by jono_misfit, on Flickr

the resistor block connections have seen better days. I'll need to do some digging as a quick search doesnt show any.

P1060615 by jono_misfit, on Flickr

P1060617 by jono_misfit, on Flickr

I got fed up playing guess the switch so got the labeling machine out.

P1060618 by jono_misfit, on Flickr

I could do with taking the dash panel out again, taping a line, and redoing them so they are all straight.

then put the dash back in

P1060620 by jono_misfit, on Flickr

and played around until it turned on

P1060621 by jono_misfit, on Flickr

some of the lights already work, which is good. (indicators for the right trun direction, and fog)

P1060623 by jono_misfit, on Flickr

But for some reason the backlight isnt coming on. I'll need to look into this as its likely a connection issue somewhere.

[jonomisfit]

I got jigy with the lathe today. I started making the adaptors from the master cylinder push rods to balance bar (to replace my shonky collection of tube nuts and threaded rod).

bored for internal thread

P1060624 by jono_misfit, on Flickr

and turned for external thread

P1060625 by jono_misfit, on Flickr

I could not get my cheapo 5/16 UNF tap & dies to cut into the metal (i used some EN24T as its highly loaded), so need to buy some decent ones to finish it off. I started to cut the external threads using the lathe but c**ked it up, so will have to turn it again.

I decided to go and start another job. I need a way to suport the weight of the fuel filler hose, most liekly onto the cage, so its not pulling on the plastic window. A inner core to support the weight of the filler tube, and and an outer tube the aluminium duct can clamp to.

Ali piece and a dodgy sketch

P1060626 by jono_misfit, on Flickr

rolling rolling rolling

P1060627 by jono_misfit, on Flickr

P1060628 by jono_misfit, on Flickr

springs onto this tube

P1060629 by jono_misfit, on Flickr

drilled some holes and marked some lines

P1060630 by jono_misfit, on Flickr

and added a couple of of beads

P1060631 by jono_misfit, on Flickr

these give clearance for a couple of cable ties to clamp it to the tube

P1060632 by jono_misfit, on Flickr

rolled some more ali

P1060633 by jono_misfit, on Flickr

cut to size and aligned

P1060634 by jono_misfit, on Flickr

welded and position the two pieces together

P1060635 by jono_misfit, on Flickr

added some beads

P1060636 by jono_misfit, on Flickr

cut some tangs

P1060637 by jono_misfit, on Flickr

welded on

P1060638 by jono_misfit, on Flickr

I was having massive issues with teh welding, then realised after this some of the dials had been nudged signifcatly out of position. I adjusted back to where they should be and it got a lot better.

and welded the two parts together

P1060639 by jono_misfit, on Flickr

Goes on like so

P1060640 by jono_misfit, on Flickr

P1060641 by jono_misfit, on Flickr

There will be a vertical support from this up to another mount on the cage.

I ran out of time, so will be on with it next time.

[jonomisfit]

made the tube clip

P1060643 by jono_misfit, on Flickr

to go here

P1060642 by jono_misfit, on Flickr

I made the bridge piece and welded it on

P1060644 by jono_misfit, on Flickr

fits like so

P1060645 by jono_misfit, on Flickr

aluminium hose vapour barrier goes over and it end up like so

P1060646 by jono_misfit, on Flickr

P1060647 by jono_misfit, on Flickr

onto the next job

spare wheel holder

P1060649 by jono_misfit, on Flickr

for in here

P1060648 by jono_misfit, on Flickr

need something like so

P1060650 by jono_misfit, on Flickr

rough cut the ali

P1060651 by jono_misfit, on Flickr

P1060653 by jono_misfit, on Flickr

sits in like so

P1060654 by jono_misfit, on Flickr

Should be doing more on the escort tomorrow

[jonomisfit]

I used the tanking dies to put a 1/2" radius on the end

P1060655 by jono_misfit, on Flickr

then marked up for some stiffening beads

P1060656 by jono_misfit, on Flickr

And got the bead roller out

P1060657 by jono_misfit, on Flickr

P1060658 by jono_misfit, on Flickr

P1060659 by jono_misfit, on Flickr

folded up the flanges

P1060660 by jono_misfit, on Flickr

test fit in the car

P1060661 by jono_misfit, on Flickr

cut some strip for the curved infill

P1060662 by jono_misfit, on Flickr

ran through the rollers

P1060663 by jono_misfit, on Flickr

sits in like so

P1060664 by jono_misfit, on Flickr

getting ready to weld

P1060665 by jono_misfit, on Flickr

first piece tacked in

P1060666 by jono_misfit, on Flickr

all tacked in

P1060667 by jono_misfit, on Flickr

fully welded in

P1060668 by jono_misfit, on Flickr

I then ran it through the tipping dies in the bead roller, followed by some stretching, dressing with hammers, and folding some flanges. Tigged a couple of seams to give

P1060669 by jono_misfit, on Flickr

P1060670 by jono_misfit, on Flickr

fixed in

P1060671 by jono_misfit, on Flickr

P1060672 by jono_misfit, on Flickr

A little bit of dressing back and tidying up to do, but has come out OK.

And works

P1060673 by jono_misfit, on Flickr

P1060674 by jono_misfit, on Flickr

I've ordered a spare wheel ratchet strap to fit to hold it down.

And trial fitted a couple of other bits

fuel pressure regulator (which I need to buy fittings for)

P1060675 by jono_misfit, on Flickr

and radiator back up into position.

P1060676 by jono_misfit, on Flickr

At some point I need to clean the engine up, replace the sump gasket with sealant and give it a trial fit, to make sure everything clears!

[jamesd1972]

Nice hi quality progress. Didn’t understand the filler hose mount until the Vapor hose got added. Is this a regulations requirement ?
James

[jonomisfit]

Generally there needs to be a barrier between fuel fill / storage and crew compartment under MSA blue book.

Mines more about I'm hoping the additional barrier will keep any fuel vapour/ smell levels in cabin down.

[jonomisfit]

It was a bit of an odds and sods day on the escort.

I started on the fuel rpessure regulator, then realised I'd forgotten to order a fitting I needed so could only make 1 pipe. Doh.

P1060677 by jono_misfit, on Flickr

the spare wheel strap turned up so fitted that.

Checking for position

P1060678 by jono_misfit, on Flickr

then bolted in

P1060679 by jono_misfit, on Flickr

holds it pretty secure when the ratchet is done up. I may still make a lower wheel fence to hold it centrally.

P1060680 by jono_misfit, on Flickr

M10 bolts to hold it down

P1060681 by jono_misfit, on Flickr

P1060682 by jono_misfit, on Flickr

P1060683 by jono_misfit, on Flickr

Then went on to remake the brake balance bar extension pieces as my hex bar & taps had turned up.

Piece 1 turned and threaded

P1060684 by jono_misfit, on Flickr

checking thread fit

P1060685 by jono_misfit, on Flickr

fits on like so

P1060686 by jono_misfit, on Flickr

and second one made

P1060687 by jono_misfit, on Flickr

P1060688 by jono_misfit, on Flickr

I could have gone down a couple of sized on hex bar, but it'll do as it is. I'll remake them if I decide grams of weight on the car are important

in situ

P1060689 by jono_misfit, on Flickr

P1060690 by jono_misfit, on Flickr

From the above I clocked I hadnt alligned the rods properly, so dismantled and did again so the bars are much closer to parallell.

I also looked at the pedal positions, and I think i need to take about 10mm from the threaded ends of the adjusters to bring it back to alignment.

mounted the brake bias adjuster

P1060691 by jono_misfit, on Flickr

P1060692 by jono_misfit, on Flickr

Mounted some pedal plates (which from the photo angle look squint, but on the car the were aligned)

P1060693 by jono_misfit, on Flickr

I moved the throttle pedal plate closer to the brake pedal to make heel and toe easier.

painted and fitted grip tape to the clutch foot rest. I bought a sheet of skateboard deck grip and cut out the size I needed. Cheep and readily replaceale when it wears out.

P1060694 by jono_misfit, on Flickr

P1060695 by jono_misfit, on Flickr

(from this pic the throttle pedal plate looks squint, so will need to go and look at that again)

then started looking at the radiator and fans

P1060696 by jono_misfit, on Flickr

took some dims

P1060697 by jono_misfit, on Flickr

started converting to aluminium

P1060698 by jono_misfit, on Flickr

fan goes like so

P1060699 by jono_misfit, on Flickr

two fans fit like so

P1060700 by jono_misfit, on Flickr

The fan kit just came with some through radiator ties to hold the fans on, but I really don't like them as they look perfect for fretting the radiator. This will be a mounting plate with a lot of cut outs and be slightly spaced off the radiator face. I'll be cutting out most of the surface to make sure the is good airflow passage.

[jonomisfit]

marking out

P1060701 by jono_misfit, on Flickr

and some more marking out

P1060702 by jono_misfit, on Flickr

start cutting to help me work out how i'm going to make it work

P1060703 by jono_misfit, on Flickr

I drilled the mounting holes, put it on the rad, then had to redrill the lower holes as they werent aligned to the top on the rad!

P1060704 by jono_misfit, on Flickr

scribbled on the ali like a mad man

P1060705 by jono_misfit, on Flickr

started drilling and cutting

P1060706 by jono_misfit, on Flickr

more cutting

P1060707 by jono_misfit, on Flickr

start folding up flanges

P1060708 by jono_misfit, on Flickr

flanges folded

P1060709 by jono_misfit, on Flickr

fans mount like so

P1060710 by jono_misfit, on Flickr

fits on like so

P1060712 by jono_misfit, on Flickr

P1060713 by jono_misfit, on Flickr

its got fairly good clearance for radiator flow, but could do with some holes on a few sections

P1060714 by jono_misfit, on Flickr

holes cut

P1060715 by jono_misfit, on Flickr

needs something more....

Swages added. much better

P1060716 by jono_misfit, on Flickr

back fitted

P1060717 by jono_misfit, on Flickr

I temporarily connected up the fans, which turn on and off fine with the override switch..... and both draw through after a quick swap of a connection....

I need to look at how i've done the temp switch control as there is no power at it, so its not swiching through for the relay.

I'll be fitting come cable clips to it, and attaching some foam on all the contact points to prevent it chaffing on the radiator. I also need to sort some spacers to hold it off the radiator the right amount.

I may have to remake it at some point as it is very very light weight, and I think with time it'll crack in places. we'll see though.

[ossiecossie]

what thickness is the aluminium ?

[jonomisfit]

Its 1.5mm thick Ali sheet.

In other news, I was out doing a few jobs on the car last night and found my wiring diagrams!

They were on top on the fuel tank..... under the tank cover.... evidently I put them there for safe keeping and put the cover on without checking!

On the plus side a check shows the bits I'd worked out match up to the diagrams. The less good news... I don't understand some of the notes I've made... 🙃

[Implandy]

having seen ac system condenser fans break brackets made of steel of similar thickness I suspect you'll be revisiting those mountsat some point

[jonomisfit]

the missing notes!

P1060718 by jono_misfit, on Flickr

fittings I needed turned up for the pressure regulator

P1060719 by jono_misfit, on Flickr

re-drilling the fuel pump mount

P1060720 by jono_misfit, on Flickr

P1060721 by jono_misfit, on Flickr

sits like so

P1060722 by jono_misfit, on Flickr

goes in here like so

P1060723 by jono_misfit, on Flickr

working out how i'm going to mount it all

P1060724 by jono_misfit, on Flickr

like so

P1060725 by jono_misfit, on Flickr

hoses and fittings all in, some hose management to do

P1060726 by jono_misfit, on Flickr

P1060727 by jono_misfit, on Flickr

I put my found notes to good use. A number of the lights on the dash arent coming on.

P1060729 by jono_misfit, on Flickr

So i used the notes, traced back the wiring and found a connector with no connection. Hmm... that shouldnt be the case. I then looked at the steering column switches link loom and went back to its connection onto the centre console.... hmm.... why is there a spare connector there..... its exactly the right mating part for the other connector about 1m away.....

I unplugged, turned it round and oh look... everything lines up. plug it in and

P1060731 by jono_misfit, on Flickr

Backlight comes on with headlight

main beam indicator comes on

P1060732 by jono_misfit, on Flickr

So do the others. I am pleased, my wiring was correct. After I fixed it....

[jonomisfit]

I fitted some spiral wrap protection to the braided hoses

P1060734 by jono_misfit, on Flickr

P1060738 by jono_misfit, on Flickr

and fited the tank straps.

P1060733 by jono_misfit, on Flickr

I still need to cut and fit the 3mm rubber under the tank hence the 3mm rubber strips under the straps. There's also a 1mm rubber strip on the underside of the straps and I've fitted 1mm rubber to the lateral mvoement tabs.

fitted the pull T-handles. Red for fire, black for isolator

P1060736 by jono_misfit, on Flickr

and routed to where the fre extinguisher will be

P1060737 by jono_misfit, on Flickr

then started marking up for the fuel guage

P1060740 by jono_misfit, on Flickr

ali
P1060741 by jono_misfit, on Flickr

P1060742 by jono_misfit, on Flickr

ready to cut for the gauge when I get it

P1060743 by jono_misfit, on Flickr

marked up the centre console showing what fuse is what

P1060745 by jono_misfit, on Flickr

P1060746 by jono_misfit, on Flickr

I stripped the blower fan again, cleaned up contacts on the motor, replaced the speed resistor (with a modified transit one as I cant find the proper one)

P1060747 by jono_misfit, on Flickr

found some holes i'd missed and put on the silver tape

P1060748 by jono_misfit, on Flickr

mounted the ECU into what was the glove box, and fitted the blanking plate to the dashboard (abeit temporarily as I havent connected it up)

P1060749 by jono_misfit, on Flickr

and painted the foot rest. I'll give it a week to cure then fit the grip tape

P1060750 by jono_misfit, on Flickr

[Darkspeed]

You need to have the clevis hard up against the pivot bush typically with large washers to prevent anything catching. If there is any space between the clevis and the bush you will have randomly altering bias as the bias bar bush is not retained in a fixed position for bias. As you only need a couple of mm - one turn of the bias adjuster typically 1mm - to give a large change in bias, there must only be enough clearance to allow full articulation of the bar and no more.

[jonomisfit]

Thanks.

I have the large washers for the balance bar to go in still. Its mainly waiting for me to take it all apart again, take 10mm off the end of adaptors I made for the push rods, and final assemble.

Usefull info to know for when I do the final assembly.

[Darkspeed]

Also remember that you will need to have a locknut on the clevis as well as your adjuster - When you have your extensions the correct length I would thread lock them onto the push rods as well as the lock nut.

[jonomisfit]

Temp fitted the front indicators

P1060751 by jono_misfit, on Flickr

to check for clearance

P1060752 by jono_misfit, on Flickr

not a huge amount of space, but it all fits

fitted skateboard grip tape to the passenger foot brace

P1060753 by jono_misfit, on Flickr

and temp fitted back in the car

P1060754 by jono_misfit, on Flickr

From memory its fairly close between the brake / clutch cylinders and the rigth bank exhaust manifold. I don't fancy them cooking so it needs a heat shield. Its a catch 22. I'd like the engine in so I can certain of space, but it'll be a pain in the backside to do with the engine in I think.

Do it whilst theres space I think. Will go here.

P1060755 by jono_misfit, on Flickr

start with the normal place

P1060756 by jono_misfit, on Flickr

goes in here

P1060757 by jono_misfit, on Flickr

P1060758 by jono_misfit, on Flickr

forget to take pictures for a while, but normal convert to aluminium, cut, fold, hammer.

gives this, although I decided to round the corners .... because....

P1060759 by jono_misfit, on Flickr

an application of the sparky hot glue gun gives

P1060760 by jono_misfit, on Flickr

drill some holes for access and drains

P1060761 by jono_misfit, on Flickr

fits like so

P1060762 by jono_misfit, on Flickr

P1060763 by jono_misfit, on Flickr

add a second bolt access hole

P1060764 by jono_misfit, on Flickr

It'll get covered with heat reflective material.... once I know there isnt an engine interference...

[jonomisfit]

I did a bit of shuffling, and cleaning(ish) of the workshop to get into this

P1060766 by jono_misfit, on Flickr

onto the engine stand.... which was a trial in itself as the hoist legs are too long to get to it properly....

P1060767 by jono_misfit, on Flickr

I'd clocked a couple of things I wanted to check so inlet manifold off

P1060768 by jono_misfit, on Flickr

which rapidly became....

P1060769 by jono_misfit, on Flickr

Why? becuase when I looked at the outlets of the thermostat block they looked properly bodged. Where the seals are there was an mix of silicone and what looked like JB weld badly applied..... and going by the marks still leaking.

One of the removed pipes

P1060770 by jono_misfit, on Flickr

you can see some of the remenants

P1060771 by jono_misfit, on Flickr

P1060774 by jono_misfit, on Flickr

assembled the block looks like so

P1060772 by jono_misfit, on Flickr

after removing the sealant and extracting

P1060773 by jono_misfit, on Flickr

I'll need to clean it all up, replace what I can (some bits are available new from Burton Power still), and find appropriate seals to go on the pipes.

The other thing I clocked was one of studs for the water elbow was sheared. I'm surprised this engine held water....

P1060775 by jono_misfit, on Flickr

tigged on a nut

P1060776 by jono_misfit, on Flickr

And it wound out nicely.

A look over the engine shows there are a few more bits to look at. Noteably there are 3 broken exhaust studs that need replaced, the water pump likely needs replaced, I think the rear crank seal needs replaced, and its been badly painted in the past and needs a proper clean down, old paint removed, and repainted. Oh, and I need to amend the fuel rail to take AN fittings... which will be fun.

I meant to take a picture, but just as well I'm replacing the fuel feed as it has chaffed almost completely through!

[mk2cossie]

Word of advice, be aware there isn't much wiggle room for fittings on the fuel rail when the inlet manifold goes back on

Good progress otherwise and I'm looking forward to videos of it running