1994 - Ford Escort Cosworth - power steering fluid tank

[jonomisfit]

I decided I fancied a change this afternoon.

If anyone has driven a sierra / escort thats got some age behind it will know the gear shift gets sloppy. Ford put a lot of rubber where they could in the gearstick, i'm asusming to reduce noise/vibration. I'm surte it was fine when new, but its all gone soft so i need to do something. It turns out i have 4 gear sticks, some better than others, but all seem a bit sloppy to me.

Think i'll make a new gear stick.

Original

P1070721 by jono_misfit, on Flickr

I've already ordered a nylon gear nob (at £20 its not worth the effort of making one!)

but need to make the stick itself. Make a drawing of waht I want.

P1070722 by jono_misfit, on Flickr

I've got a length of 20mm EN24T lying about, so am makling from this. Considerably stronger than normal bright mild so if it bends, i've likely bent a selector fork as well.

Cut to length and put in the lathe

P1070723 by jono_misfit, on Flickr

cut a step and doing a light pass with the thread tool to check pitch correct

P1070724 by jono_misfit, on Flickr

P1070725 by jono_misfit, on Flickr

threads cut

P1070726 by jono_misfit, on Flickr

reducing centre section

P1070727 by jono_misfit, on Flickr

part made, couple of flats added to bottom

P1070728 by jono_misfit, on Flickr

P1070729 by jono_misfit, on Flickr

pretty much finished, but may need a few light tweaks when the gear knob turns up

drilled for a sping pin

P1070730 by jono_misfit, on Flickr

and fitted

P1070731 by jono_misfit, on Flickr

P1070732 by jono_misfit, on Flickr

Its come out quite nicely and feels rock solid.

I've got a metal blacking kit coming, so will be taking it off, cleaning, and doing a chemical black to protect it a bit.

Hopefully the gear knob will fit.....

[mk2cossie]

The BOA definitely had cats in the downpipe section as standard.
Can't remember if they had a third shared one further back tho 🤔

Either way, I'd make new downpipes from 2inch pipe, and make it where you want to go and clear things

If the Escort is registered after 1994, it only needs 1 cat anyway

[jonomisfit]

Its interesting, when I was doing a search for Granada Cosworth catalytic converter it doesnt return anything. The only ones listed are the scorpio cosworth ones for the BOB.

I've been looking at exhaust tube / bends kits and will make something :-)

[kevins]

Originally it would have had 4 catalysts.

[jonomisfit]

Those are the bits I have (1 and 2) but none of them have cats in them. They are empty boxes.....

Unless the cats have failed and been blown out, or someone has pulled the internals out.

[mk2cossie]

Apr 3, 2023 9:18:38 GMT jonomisfit said:

Those are the bits I have (1 and 2) but none of them have cats in them. They are empty boxes.....

Unless the cats have failed and been blown out, or someone has pulled the internals out.

I think we all know what happened to the innards

Also means the exhaust would drone too, as the hollow chambers cause all kinds of reverberation noises when cruising

[jonomisfit]

Apr 3, 2023 11:55:20 GMT mk2cossie said:

Apr 3, 2023 9:18:38 GMT jonomisfit said:

Those are the bits I have (1 and 2) but none of them have cats in them. They are empty boxes.....

Unless the cats have failed and been blown out, or someone has pulled the internals out.

I think we all know what happened to the innards

Also means the exhaust would drone too, as the hollow chambers cause all kinds of reverberation noises when cruising

😆😆😆

[kevins]

yep there is supposed to be a small light off cat in the front ones and larger bricks in the ones further back.

[jonomisfit]

My M10x1.5 die turned up so used it to finalise the thread profile. It took a very small amount out and left a good fit on a nut

P1070736 by jono_misfit, on Flickr

P1070737 by jono_misfit, on Flickr

I took out the last couple of threads to prevent a stress raiser

P1070738 by jono_misfit, on Flickr

then test fitted the internal from the gear knob

P1070739 by jono_misfit, on Flickr

goes on like so

P1070740 by jono_misfit, on Flickr

But a raw steel shaft is going to go rrange very quickly.

Time for some alchemy

P1070741 by jono_misfit, on Flickr

some detailed instructions..

P1070742 by jono_misfit, on Flickr

Basically clean for 10 mins, in the blue solution (copper selenide) for 10, and oil for 10.

clean

P1070743 by jono_misfit, on Flickr

dried

P1070745 by jono_misfit, on Flickr

Just into the blue

P1070746 by jono_misfit, on Flickr

10 mins in the blue

P1070747 by jono_misfit, on Flickr

rinsed

P1070749 by jono_misfit, on Flickr

de-watering oil

P1070750 by jono_misfit, on Flickr

cleaned part

P1070751 by jono_misfit, on Flickr

its come out OK.

Goes well with the gear knob

P1070752 by jono_misfit, on Flickr

I'm going to give it a coat of matt laquer to protect it, as I think it'll corrode with time still otherwise.

I need to deal with this hole as will let in fumes.

P1070744 by jono_misfit, on Flickr

I have this bit, which has a plastic insert, but doesnt fit my car, but is close enough to use

P1070748 by jono_misfit, on Flickr

I need to make a bracket

P1070753 by jono_misfit, on Flickr

mark out some 3mm ali

P1070754 by jono_misfit, on Flickr


roughly trimmed

P1070755 by jono_misfit, on Flickr

bent some alignment tabs

P1070756 by jono_misfit, on Flickr

and in situ

P1070757 by jono_misfit, on Flickr

and gearstick in

P1070758 by jono_misfit, on Flickr

I think its come out quite well

P1070759 by jono_misfit, on Flickr

P1070760 by jono_misfit, on Flickr

Doing some brum brum noises the gearstick is a massive improvement over the original. No flex, very positive shifting, and just the right length for me.

[jonomisfit]

Then it was on to the sump guard whilst it accessible. I need to do this so I can make sure I position a few other things and I need to make sure they don't hit the sump guard.

Club sump guards are usually made from 6mm duralluminium for wear resistance, or laminated from kevlar, but i'm making mine from a couple of pieces of regular 3mm Ali welded together. Its just there to offer a bit of protection for the lows.

Going to be something like this

P1070762 by jono_misfit, on Flickr

mark out some Ali sheet

P1070761 by jono_misfit, on Flickr

trimmed to shape with the jigsaw

P1070763 by jono_misfit, on Flickr

got out the old sheet metal folder I made as it was big /sturdy enough

P1070764 by jono_misfit, on Flickr

first slilght bend in and in position

P1070765 by jono_misfit, on Flickr

P1070766 by jono_misfit, on Flickr

the front curved bit was more of a challenge to make, but I did 5 off circa 8 degree bends to make the curve

P1070767 by jono_misfit, on Flickr

and then dressed it

P1070768 by jono_misfit, on Flickr

A bit more shaping needed, then i'll do the fixings

P1070768 by jono_misfit, on Flickr

[jonomisfit]

I kocked some transfer punches up and marked out and drilled mounting bolt holes.

P1070771 by jono_misfit, on Flickr

Plate back up with temp bolts

P1070769 by jono_misfit, on Flickr

gives 25mm clearance to the bottom of the subframe and about 35mm to the bottom of the sump

P1070770 by jono_misfit, on Flickr

used some more transfer punches on the rear and marked the sump guard

P1070772 by jono_misfit, on Flickr

P1070773 by jono_misfit, on Flickr

drilled

P1070774 by jono_misfit, on Flickr

with a second skin the countersink bolt will sit flush

P1070775 by jono_misfit, on Flickr

folded up the rear corners

P1070776 by jono_misfit, on Flickr

P1070777 by jono_misfit, on Flickr

then onto the side stiffener plates

rear sections, marked

P1070778 by jono_misfit, on Flickr

trimmed

P1070779 by jono_misfit, on Flickr

transfer to the other side

P1070780 by jono_misfit, on Flickr

both trimmed

P1070781 by jono_misfit, on Flickr

stitch welded on

P1070782 by jono_misfit, on Flickr

I was struggling to get nice clean welds, and after much tweaking got it running OK but not amazingly.

P1070783 by jono_misfit, on Flickr

in situ

P1070784 by jono_misfit, on Flickr

P1070785 by jono_misfit, on Flickr

I may need to add slightly more clearance around the compression strut rode end

from underneath

P1070786 by jono_misfit, on Flickr

starting to shape the next section

P1070787 by jono_misfit, on Flickr

P1070788 by jono_misfit, on Flickr

getting the front curve set

P1070789 by jono_misfit, on Flickr

P1070790 by jono_misfit, on Flickr

more fettling

P1070791 by jono_misfit, on Flickr

P1070792 by jono_misfit, on Flickr

welded up and tweaking fit

P1070793 by jono_misfit, on Flickr

P1070794 by jono_misfit, on Flickr

front needs trimmed to shape

P1070795 by jono_misfit, on Flickr

We'll see how I get on next sesuion.

[ossiecossie]

did you buy or make the sump guard brackets the thick aluminium ones?

[jonomisfit]

I bought them.

I got them from a rally page on Facebook, but I think ATM / Prestige motorsport do them.

[jonomisfit]

Dropped the sump guard back down again and set up on the bench for welding

P1070796 by jono_misfit, on Flickr

started welding the side onto the sump guard

P1070797 by jono_misfit, on Flickr

start cutting out the other side reinforcing

P1070798 by jono_misfit, on Flickr

many cuts

P1070799 by jono_misfit, on Flickr

tacked together and clamped into position

P1070800 by jono_misfit, on Flickr

P1070801 by jono_misfit, on Flickr

clamped ready for welding on

P1070802 by jono_misfit, on Flickr

adding additional welds

P1070803 by jono_misfit, on Flickr

back in to check what tweeks are needed

P1070804 by jono_misfit, on Flickr

back on the bench and stitch weld the reinforcing edge

P1070805 by jono_misfit, on Flickr

P1070806 by jono_misfit, on Flickr

P1070807 by jono_misfit, on Flickr

aaaaaaand ran out of gas just as I got the last welds done. Will need to get more as I have additional strips to fit on the sump still

Sump guard back on

P1070808 by jono_misfit, on Flickr

P1070809 by jono_misfit, on Flickr

P1070810 by jono_misfit, on Flickr

P1070811 by jono_misfit, on Flickr

Its coming on OK.

Still pretty light in weight.

[danknight]

great thread this some great fabrication , not sure 3mm sump guard would be any use on the rallies i have done!

[jonomisfit]

Agreed, 3mm wont stand up to much. Its going to have a second 3mm skin added in key places, plus some 6mm skids / ribs applied as well. I am however now stuck waiting for material to turn up and also more gas.

[jonomisfit]

Today was a fill in day as I'm waiting for more gas to turn up.

my box of exhaust bits arrived

P1070812 by jono_misfit, on Flickr

I fitted the bar I used to position the rear sump guard mounts, as this is sets the plane for the sump guard that the exhasut has to clear.

P1070813 by jono_misfit, on Flickr

it doesnt fit as is so needs a trim

P1070814 by jono_misfit, on Flickr

Oh, and this is why there is no cat present in it

P1070815 by jono_misfit, on Flickr

cut and cleaned

P1070816 by jono_misfit, on Flickr

cut a 45deg bend in two

P1070817 by jono_misfit, on Flickr

And added a wedge to change the angle of the pipe in two direction, and used tape to temporarily hold in place. This side has loads of space.

P1070819 by jono_misfit, on Flickr


This side does not....

P1070820 by jono_misfit, on Flickr

not quite as bad as it looks here, but still pretty tight round the prop and tunnel

P1070821 by jono_misfit, on Flickr

I bought a couple of weld in silencers, however they are too big for my original intention

P1070822 by jono_misfit, on Flickr

nicely sized to allow the pipe to slot into it for welding

P1070823 by jono_misfit, on Flickr

Because its so tight round the gearbox / tunnel this side I need to make it turn in two directions

P1070823 by jono_misfit, on Flickr

P1070825 by jono_misfit, on Flickr

I was trying to work out what I need to aim the pipe at, so put the silencer in positon where I wanted it to be

P1070826 by jono_misfit, on Flickr

its all very tight

P1070827 by jono_misfit, on Flickr

P1070828 by jono_misfit, on Flickr

P1070829 by jono_misfit, on Flickr

I'm not sure I want it hanging down as low as it is. I need to find some oval silencers, however they don't seem to be that easy to get hold of.

I'll do some searching to see what I can find.

I need to get past the edge of the gearbox so need to make a bubble.

Using tape to work out centre points

P1070830 by jono_misfit, on Flickr

cut on lines intersecting with this and taped together

P1070831 by jono_misfit, on Flickr

and tacked

P1070832 by jono_misfit, on Flickr

goes in like so

P1070833 by jono_misfit, on Flickr

tight, but clears with some room to move

P1070834 by jono_misfit, on Flickr

I got fed up with the tapering wedge under the car, so put in the rear stands

P1070835 by jono_misfit, on Flickr

P1070836 by jono_misfit, on Flickr

Will see how I get on next time I'm in the workshop.

[jonomisfit]

It been a busy week or so, but managed to get an hour in the workshop.

I need a cross over pipe, but cant find anything that works for me.

I have these though

P1070837 by jono_misfit, on Flickr

and a saw

P1070838 by jono_misfit, on Flickr

I need two of these

P1070839 by jono_misfit, on Flickr

the bends arent especially accurate so one needed a slight tweak to get them parallell

P1070840 by jono_misfit, on Flickr

Marking out for cutting

P1070841 by jono_misfit, on Flickr

cut and cleaned up

P1070842 by jono_misfit, on Flickr

P1070843 by jono_misfit, on Flickr

second side cut

P1070844 by jono_misfit, on Flickr

cleaned up, tweaked, then welded the joint

P1070845 by jono_misfit, on Flickr

I need to tweak it a bit further , but that was all I had time for today.

[Darkspeed]

Nice bit of design assembly work going on there - as usual I may add - Anther reason I like mid engine and rear engine cars - no room for that sort of faffing about creative fabrication needed

[jonomisfit]

Haha, it's the journey not the destination for me.

Inventing side projects is what keeps it fun.