Escort RS2000 4x4 2.0 Turbo Conversion

[shaneovhx]

Hi I'd just like to ask you a question if you don't mind, I've got a mk6 3dr escort but want it converting to a 4x4 with some sort of turbo engine, the escort is in great shape apart from both sills need doing, how much would you charge to do all the work and fit fiberglass f2 maxi bodykit to the car aswell, if you want to email me with any questions my email address is shanejunior2012@gmail.com, I appreciate it very much.

Thank you. Shane.

[jdunn91]

Been following this since day 1, how is the progress coming?

 

What clutch do you recommend when replacing/upgrading on the rs2000 4x4?

 

Thanks

[blacksofstichill]

Hi I'd just like to ask you a question if you don't mind, I've got a mk6 3dr escort but want it converting to a 4x4 with some sort of turbo engine, the escort is in great shape apart from both sills need doing, how much would you charge to do all the work and fit fiberglass f2 maxi bodykit to the car aswell, if you want to email me with any questions my email address is shanejunior2012@gmail.com, I appreciate it very much.

Thank you. Shane.

 

Hi Shane, sorry, I just noticed your message, that sounds like a pretty major project!  I'll drop you an email and see if you're still going ahead with it....cheers!

 

Been following this since day 1, how is the progress coming?

 

What clutch do you recommend when replacing/upgrading on the rs2000 4x4?

 

Thanks

 

 

Thanks for following the project, much appreciated!  I think the standard clutch is still good for something mildly tuned (lets say to around 180bhp) but for something turbo'd I'd say that the clutch we fitted to this from CG motorsport is a good bet, it isn't too heavy for driving in traffic, etc and will be good for a much higher power output than standard.

 

Time for a long overdue update -

 

Just a small update on this, I had some time to tie up some of the loose ends in the engine bay, starting with the throttle cable. The original one on the car was frayed at the end -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01747.JPG

 

Not only that but I found when I tried to fit it to the Cosworth Throttle Body it was right at the end of it's adjustment which was odd as I'd made the bracket so it was in the middle of it's adjustment. However, when I compared the car's cable to another RS one I had in stock I found it was around 20mm shorter -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01748.JPG

 

So, the replacement cable was fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01749.JPG

 

Alternator connected up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01750.JPG

 

Starter Motor connected up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01751.JPG

 

Alternator end cover/heat shield cleaned ready for refitting -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01752.JPG

 

And fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01753.JPG

 

Power Steering Pipes Connected at the rack end -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01754.JPG

 

And the Cooler Pipes connected and refitted at the front -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01755.JPG

 

With another Gearbox Mount here I was able to crack on and get some more bits fitted, Gearbox mount as delivered -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01756.JPG

 

It was in good working order but cosmetically it was just what you'd expect it to be, luckily we had some powder coated parts in stock to help change that -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01757.JPG

 

"New" Mounting removed from it's bracket -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01758.JPG

 

Primed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01759.JPG

 

and Painted in Satin Black -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01760.JPG

 

Old Mounting with broken stud removed from the car -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01761.JPG

 

And new mounting all built up ready to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01762.JPG

 

Mounting fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01763.JPG

 

Heater Matrix Hoses fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01764.JPG

 

Gear Linkage fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01765.JPG

 

Propshaft fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01766.JPG

 

Another present from Olly arrived in the Post -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01767.JPG

 

A nice new Radiator -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01768.JPG

 

Fitted to the car, all the hoses lined up so my pipework alterations for a coolant feed to the turbo seem to have worked -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01769.JPG

 

Plenty of clearance between the Turbo and the Radiator -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01770.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01771.JPG

 

Header Tank as removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01772.JPG

 

Cleaned up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01773.JPG

 

and fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01774.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01775.JPG

 

 

[scottybo]

This is going to be a seriously rude escort

[blacksofstichill]

Next up was our intercooler and Pipework, this lot all came with the Engine Olly originally bought and although I had trial fitted it to the engine when it was on the stand I had never been able to trial fit it on the car until now -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01776.JPG

At this stage I only have the intercooler cable tied to hold it up and the hoses are just pushed into place rather than clipped. All I wanted to see was that it would be able to fit in the way we wanted it to before I tidied all of the pipework up -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01777.JPG

I'm pretty happy with it in as much as it means I don't have to start making up pipework and trying to get it all to line up from scratch. Using what we have here with some alterations to the power steering cooling pipe mounting position should work a treat and still leave us with room for an oil cooler and Cooling Fan -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01778.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01779.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01780.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01781.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01782.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01783.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01784.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01785.JPG

 

 Olly had sent up these lovely slimline Kenlowe Fans and we ambitiously hoped to fit them both side by side in front of the radiator -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01786.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01787.JPG

These 2 plastic lugs on the end of the radiator lended themselves perfectly for mounting one end of the first fan -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01788.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01789.JPG

With the 2nd fan alongside it we managed to fit it in within the core of the radiator without overlapping past the end of it -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01790.JPG

These are fitted using the supplied cable tie style ratchet fittings through the radiator core -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01791.JPG

Time to take a step back and see how they look -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01792.JPG

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01793.JPG

 

[scottybo]

Intercooler looks a little on the small side i would have thought. But it does look really deep

[blacksofstichill]

Intercooler looks a little on the small side i would have thought. But it does look really deep

 

Yeah, you're right, it's not the largest intercooler out there but is very deep, we didn't want to have a huge intercooler that we'd struggle to fit in if you know what I mean.

 

Another one of Ollys purchases arrived, A Setrab Oil Cooler -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01794.JPG

 

And also a Mocal Fitting Kit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01795.JPG

 

Oil cooler fits nicely above the intercooler, here it is laid into place, some alterations are needed but you get the rough idea -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01796.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01797.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01798.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01799.JPG

 

With the basic rough layout of everything decided it was time to bracket up the intercooler properly, suitable section of flat bar cut -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01800.JPG

 

And bent into shape -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01801.JPG

 

Holes drilled to suit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01802.JPG

 

Painted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01803.JPG

 

And fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01804.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01805.JPG

 

Intercooler lower pipe also bolted up to the bottom of the intercooler -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01806.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01807.JPG

 

Pipes fitted to the Oil Cooler ready for a trial fitting -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01808.JPG

 

Cooler won't sit properly due to fouling on intercooler brackets -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01809.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01810.JPG

 

Mocal Kit includes these flat bars to be used for bracketing the cooler up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01811.JPG

 

Top of cooler notched out to clear intercooler bracket -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01812.JPG

 

Mocal Mounting brackets cut and folded into shape -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01813.JPG

 

Brackets bolted up to the Cooler -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01814.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01815.JPG

 

Brackets bolted to the crossmember -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01816.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01817.JPG

 

Cooler Pipes are close to the Fan but the do have clearance and both are in fixed positions -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01818.JPG

 

Power Steering Cooler Pipes bolted up to the bottom off the Oil Cooler which allows them to it in front of the intercooler -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01819.JPG

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01820.JPG

 

 

[malfis]

Im curious how you will fit front bumper 

[scortpower]

Wow I've not been on this forum for years but I have just gone through all 16 pages of this build! brilliant work. Will keep an eye on this now.

[scottybo]

Paint the intercooler. It looks ratty compared to everything else