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A bit of useful information for anyone building an Escort Cosworth Rep


muz

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I'm currently building an Escos replica for a run around and was surprised at the lack of information regarding the fitting of genuine parts in conjunction with replica bits so just sharing some useful information on how to make the front end more convincing as the proportions are totally different due to the Sierra floorpan and genuine front bumper fitting.

 

After test fitting the front bumper I've discovered a few things. The replica bumpers are totally different to genuine bumpers (obviously as the chassis is Sierra not Escort) but I didn't realise just how different!

 

Firstly, the dimensions are very different. The genuine bumper is far shallower (about 2 inches) from the wheel arch to the front. This is to take up the distance to the wheel arch as the front section of replica wings is longer behind the sidelight so the wheel sits in the centre of the arch and is also why replicas using genuine wings and front bumpers have the wheel too far back in the arch. Found some good examples below in the same colours with the same wheels;

 

Real Escort Cosworth;

 

http://img.photobucket.com/albums/v86/cossiecrew/Picture008.jpg

 

Replica with genuine wings and bumper;

 

http://i39.photobucket.com/albums/e197/jjperformance/Picture003-16.jpg

 

Replica with replica wings and replica bumper;

 

http://i158.photobucket.com/albums/t115/ciscokid_bucket/g.jpg

 

You can see that when you compare them they are all very slightly different and this is one of the reasons replicas never look quite right. The proportions aren't quite as they should be at the front because of the different wing lengths which requires a deeper bumper. But theres more...

 

Secondly, the heights of the bumpers are also different. On real cars the front bumper should be level with the sideskirts. On replicas they aren't. This is because of the foglights. The fogs in the bumper are in different places on a genuine bumper and a replica designed for a FWD car due to them fouling on the FWD front crossmember as I found out yesterday, so on a replica bumper they set the fog lights about 15mm lower in the bumper which makes the space above them too big as they also have to move the smaller grille down to keep that in line. This then leaves the manufacturer with two options, either make the cut out at the bottom smaller (as shown in the bottom photos) which completely changes the shape of the bumper, or make the bumper longer so the proportions from the front look fine, but then look weird from the side (as can be shown on the red car above, then bumper is too long)

 

Genuine front bumper;

 

http://www.rscosworthbreakers.co.uk/new%20unit%20parts%20029%20(Small).jpg

 

Replica front bumper with shallower bottom grille.

 

http://media.turbosport.co.uk/2007/1/2007012121405313111CIMG2019.JPG

 

What I plan to do (as my genuine bumper is pretty smashed up) is to cut it about 2 inches in from the wheel arch and extend it back so it fits properly. I will then cut the crossmember so the fog lights fit in and re brace it properly like the lads have done who have used genuine bumpers and mine should then be a cross between the two. Hopefully as the proportions will look right on the front with regards to fog light position, grill size and correct height with regards to the sideskirts the difference in wing length shouldn't be too noticeable.

 

I thought this is quite a good write up for anyone who has or was thinking about building a replica as to why the front ends never look correct unless a lot of money is spent using genuine wings, bumpers and custom lower arms to set the wheel in the arch correct like the one below;

 

Probably THE best replica ever built;

 

http://i49.photobucket.com/albums/f277/zetecturbo1/195.jpg

 

Happy reading guys. :king:

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I've had to reps in the past, one good, one bad, building a third now which is actually Dubs old black shell from here. Everyone I've seen just didn't look right. Something about the proportions of the car just weren't right and now I've sussed it. It's the complete front end. When you look at the pictures above and how much shorter the genuine front end is it's obvious. I just couldn't see it until I went to fit my genuine bumper and it was too short as my wings are fibreglass replicas.
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It all comes down to the wheel base really, the Cosworth wheelbase is only 1" longer.

 

http://www.orioncosworth.co.uk/images/galleries/adrenalineraceperformance/1239469009-img_3488.jpg

Odd way of showing it I know !

 

By moving the wheel forward, you can use Cosworth parts and make it look right.

 

http://www.orioncosworth.co.uk/images/galleries/cjtallispaintshop/1239472409-img_4519.jpg

http://www.orioncosworth.co.uk/images/galleries/cjtallispaintshop/1239472371-img_4881.jpg

I'm not quite sure why, but I don't have a side on picture.

 

We've moved this topic into the correct section.

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This is a great thread! I would open a topic about it lol

Could you help me with this: I wonder which parts of genuine cosworth will fit and what parts will NOT fit in a standard Escort shell?

 

Here is the list (genuine cosworth):

 

front arches?

rear arches?

whaletail?

tailgate?

front bumper?

rear bumper?

side skirts?

wheels?

Edited by True Blue
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Finally someone.. lucky im going for the wrc rep for the time bein..but usefull for if i fancie a change...where do these custom lower arms come from??

 

 

Nice Orion! Looks lovely.

 

Exactly, wheelbase is different which means it has to "absorbed' into the body kit which puts the whole front end out of proportion when using non genuine parts. It makes me want to use real front arches now... How did you go about moving the wheel forward?

I have the Escort Cosworth subframe fitted

 

http://www.orioncosworth.co.uk/images/galleries/thebuild2009/1243368799-img_2653.jpg

http://www.orioncosworth.co.uk/images/galleries/thebuild2009/1243524770-img_2689.jpg

http://www.orioncosworth.co.uk/images/galleries/thebuild2009/1243524829-img_2696.jpg

 

I imagine it would be quite a task to do on a FWD car, I presume altering the front arms will cause all kinds of geometry issues.

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It will all fit, just you might have to fettle some bits to make them fit. The sideskirts *i think* need to be shortened slightly.

 

Ok, so just the sideskirts and front bumper need to be shortened? the rest should fit without any difference?

Edited by True Blue
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It will all fit, just you might have to fettle some bits to make them fit. The sideskirts *i think* need to be shortened slightly.

 

Ok, so just the sideskirts and front bumper need to be shortened? the rest should fit without any difference?

 

I haven't actually measured a genuine and replica side skirt so I'm not sure. I'm 99% sure though that the rear quarter panels are identical in size etc, they are just wider.

 

The front bumper needs Extending if you are using replica wings with a genuine bumper. If they are genuine wings it will fit fine, however the wheel wont be central in the arch and a section of chassis rail needs cutting out as it fouls the fog light section of the genuine bumper.

 

The boot lid and spoilers fit fine, mine are genuine Escos on mine.

 

The front grille *I think* fits fine although as I don't have headlights currently I have been unable to see.

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It will all fit, just you might have to fettle some bits to make them fit. The sideskirts *i think* need to be shortened slightly.

 

Ok, so just the sideskirts and front bumper need to be shortened? the rest should fit without any difference?

 

I haven't actually measured a genuine and replica side skirt so I'm not sure. I'm 99% sure though that the rear quarter panels are identical in size etc, they are just wider.

 

The front bumper needs Extending if you are using replica wings with a genuine bumper. If they are genuine wings it will fit fine, however the wheel wont be central in the arch and a section of chassis rail needs cutting out as it fouls the fog light section of the genuine bumper.

 

The boot lid and spoilers fit fine, mine are genuine Escos on mine.

 

The front grille *I think* fits fine although as I don't have headlights currently I have been unable to see.

 

 

thanks for all information.

Do you have more pictures of this car?

http://i49.photobucket.com/albums/f277/zetecturbo1/195.jpg

 

Is it also using the genuine cosworth front bumper? the wheel seems to be right central.

 

EDIT: is the cosworth bonnet the same size?

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It's probably the best rep that's been built. Every single piece on it is genuine. He said the wheelbase has been altered to get the wheels central but I don't know any more than that.

 

http://i49.photobucket.com/albums/f277/zetecturbo1/192.jpg

 

http://i49.photobucket.com/albums/f277/zetecturbo1/193.jpg

 

http://i49.photobucket.com/albums/f277/zetecturbo1/194.jpg

 

http://i49.photobucket.com/albums/f277/zetecturbo1/196.jpg

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It's probably the best rep that's been built. Every single piece on it is genuine. He said the wheelbase has been altered to get the wheels central but I don't know any more than that.

 

Thanks for the photos. Actually this is very well made replica, looks great!

 

I also have some pictures of other nice replicas:

http://i.imgur.com/I3A0p.jpg

http://i.imgur.com/e6dWo.jpg

http://i.imgur.com/Ln3Mt.jpg

 

I have more pictures and they look very aligned, especially in the front. I just can't tell if they were made with the genuine cosworth parts like that red.

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