Escort RS2000 4x4 2.0 Turbo Conversion

[Craig855S]

Fantastic thread so far, love things like this. Will you be using new rings with your newly bored out engine or just reusing the old ones?

[blacksofstichill]

Keep it coming!

 

Will do, thanks!

 

 

Ohhhh, I've been looking forward to this post!

 

Thanks, there's loads of work to do on this so there'll be plenty of updates!

 

 

Oh no, I kept scrolling and it stopped

 

Ha ha, sorry about that, by the time I've finished there'll be plenty of pics and reading in this!

Fantastic thread so far, love things like this. Will you be using new rings with your newly bored out engine or just reusing the old ones?

 

Thanks, glad you find it interesting. In pretty much any other case I'd say to fit new rings every time, even more so if the bore has been scored. However, in this case I'm going to re-use the existing rings, the reason for this is that although the bores are scored the pistons and rings are pristine with no marks or scoring on them, basically from what the owner of the car found out from an Arias dealer the Pistons were not from the engine's original build, they were a new order at a later date.

My understanding of it is that the first set of pistons caused the bore damage and a second set were ordered to replace them and subsequently fitted (they should really have rebored and fitted oversize pistons at that stage) but the engine can't have been ran for any time at all with these new pistons, the scores on the bores are so bad the pistons would have "picked up" on the bores and scored the pistons too if it had been ran for any length of time.

 

So, it's now time for a much overdue update on this engine as quite a bit of work has gone on since my last update! As you may remember the original block was scored and since we are re-using the forged pistons we decided to start with a fresh block and bore it out to suit. So, I picked out the best block I had which was in the best cosmetic condition to minimise the amount of time needed to clean it up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0080.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0081.jpg

 

So, it was into the workshop -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0082.jpg

 

And out with the boring bar -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0083.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0084.jpg

 

Original bores were in really good condition which is a shame since we are boring out anyway -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0085.jpg

 

Since I had last used the boring bar on a crossflow bore I needed to remove the 3 "cats paws" which centralise the bar in the bore so I could fit larger ones to suit the larger RS bore -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0086.jpg

 

Cats Paws removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0087.jpg

 

A quick look at the toolkit for the boring bar -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0088.jpg

 

The correct set of cats paws were selected -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0089.jpg

 

And fitted to the bar -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0090.jpg

 

Correct size of bore clamp selected -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0091.jpg

 

And clamped into the bore of No 3 Cylinder, the small "foot" of the clamp locks in at the bottom of the bore and the "finger" is screwed out until it clamps tightly into the bore -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0092.jpg

 

The top clamp slides over the bore clamp with the large round screw head of the bore clamp locating into the T-slot on the bottom side of the top clamp.

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0093.jpg

 

The Top Clamp then slides into the bottom of the boring bar and is tightened down the clamp the bore to the block, at this stage though the top clamp is left slack until the bar is centralised in the bore -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0094.jpg

 

Boring Bar over No 1 cylinder ready to lower it into the bore -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0095.jpg

 

Entering the bar into the bore -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0096.jpg

 

With the bottom of the bar half way down the bore, the cats paws are screwed out to centralse the bar on no 1 bore -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0097.jpg

 

And then the Top Clamp is tightened up to hold the boring bar in place on the block -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0098.jpg

 

The correct size of cutting tool is selected -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0099.jpg

 

It is then adjusted to the correct length and set to that length in a special micrometer which reads the size the bar will cut at -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0100.jpg

 

The grub screw on the side of the cutting tool is tightened up once the tool length is set so that it stays locked in place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0101.jpg

 

Boring bar ready to have the cutting tool fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0102.jpg

 

Fitted and locked into place with a grub screw on the side of the boring bar -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0103.jpg

 

First Cut being taken here, we need to bore this out by 0.5mm so my first "roughing cut" is 0.375mm which leaves 0.125mm for a finishing cut -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0104.jpg

[ganges]

sod the haynes manual, have you thought about writeing a book, this is high detail at its best, love it, and thats coming from a lay man, keep it coming

[Craig855S]

Thanks, I'd always wondered what kind of tool was used for rebores and how it was set up and now I know. How much is this bit of kit worth?

[blacksofstichill]

sod the haynes manual, have you thought about writeing a book, this is high detail at its best, love it, and thats coming from a lay man, keep it coming

 

Thanks, really appreciate that and pleased to hear you like the detail in the project, I've not thought about writing a book though! On another forum I use some people have actually said they don't like me putting up so many photos of the work I do.

 

Thanks, I'd always wondered what kind of tool was used for rebores and how it was set up and now I know. How much is this bit of kit worth?

 

Cool, this is one of the reasons I put a lot of effort into detailing my work, it's sometimes the only chance people have of seeing how some jobs are done so I'm glad it's been helpful to you. I've no idea how much the boring bar and tooling for it is worth though, this one will have been at the garage since around the early 70's at a guess, I've got a book with it showing the jobs it did in the 50's and 60's before my Dad and Uncle bought it, so it's a fair age!

 

bit more to show here, First cut taken and you can see the difference in bore finish -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0105.jpg

 

Cutting tool reset in the micrometer to take the finishing cut -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0106.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0107.jpg

 

Bar set up ready to take the finishing cut -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0108.jpg

 

Finishing cut taken -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0109.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0110.jpg

 

Bore diameter checked with the internal micrometer, you'll see that the bore is still 0.01mm undersize, this is the alowance I have made for material removed during honing -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0111.jpg

 

Then the boring bar is all set up on No 2 cylinder and the same process is carried out on the rest of the bores -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0112.jpg

 

All 4 cylinders bored -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0113.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0114.jpg

 

Next up the Honing Bar comes out to finsh the bores off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0115.jpg

 

Ready to enter it into the Bore -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0116.jpg

 

Entered into the bore, centralised and expanded out to meet the bore walls -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0117.jpg

 

And working up and down the bores -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0118.jpg

 

Bore sizes re-checked with the micrometer and you can see they are now right on the 86.50mm mark -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0119.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0120.jpg

 

All 4 bores honed out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0121.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0122.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0123.jpg

 

More updates as soon as I can, cheers!

[lee grout]

Love it.......nuff said

[Craig855S]

Awesome, more intresting stuff, is that honing bit just a smooth grinding stone or something?

[blacksofstichill]

Love it.......nuff said

 

Cheers, much appreciated!

 

Awesome, more intresting stuff, is that honing bit just a smooth grinding stone or something?

 

Thanks, yes, the Honing sticks are basically very smooth grinding stones, in this case their job is to smooth the bore out as the boring bar cutting tool leaves the bore with tiny grooves all the way down it, the hone smooths off the high spots and brings the bore to it's final size.

[blacksofstichill]

Another small update for you, with the engine bored out and honed it was time to put it on the stand to do some more work on it, engine stand bracket bolted on -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0124.jpg

 

And onto the stand -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0125.jpg

 

Looking at the front of the block, I need to add in an Oil Return from the Turbo in the new Block -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0126.jpg

 

A quick look at the original block shows it was in the bottom right corner of the block but with a steeply angled return pipe, a bend like that isn't great for a gravity flow -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0127.jpg

 

So, going back to the new Block, I decided to use the same location for the return pipe and centre drilled into the block -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0128.jpg

 

Drillled out with a Pilot Drill -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0129.jpg

 

Drilled out to 18.5mm -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0130.jpg

 

And Reamed out to 19.05mm (3/4"), I decided to make the return hole as large as possible as I'll be making a spigot to suit rather than re-using the existing pipe -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0131.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0132.jpg

 

And viewed from the inside of the block you can see it enters just within the line of the sump sealing face -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0133.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0134.jpg

 

So, now I have to make a spigot to suit that I can fit into the hole in the block and be able to attach an oil return pipe onto it, so, starting off with some 7/8" round stainless bar -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0135.jpg

 

And onto the lathe it goes -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0136.jpg

 

One end faced off and turned down to size -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0137.jpg

 

And turned around to machine the other end down to size too -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0138.jpg

 

Bored up the middle to 5/8" (approx 16mm) diamater -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0139.jpg

 

And that's the finished article -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0140.jpg

 

Roughly held in place to give you an idea of how it will look -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0141.jpg

 

So, with that out of the way it's time to clean the block up ready for painting, here it is before I started, not the worst block I've seen but still needs to be well cleaned before it can be painted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0142.jpg

 

To clean it up, remove all the paint and any scales of rust I used this Sealey Air Needle Scaler, I've had it for years but never used it until now but I'm really impressed with the job it did -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0143.jpg

 

First Side of the block cleaned up and you can see a noticeable difference -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0144.jpg

 

Onto the second side, the back of the engine is never as bad as the front -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0145.jpg

 

And all cleaned up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0146.jpg

 

After this I took it off the stand and washed it all inside and out with degreaser to get rid of any filings from the machining process and to wash it down ready for painting -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0147.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0148.jpg

[sidrick]

A genuine thank you for documenting your builds here. Giving enthusiasts a chance to see the processed that we wouldn't normally get a chance to.

 

You also look like you do things the right way, something that seems to be rare nowadays

[HIGHTOWER]

I can only echo what others have said! These threads are fantastic? Who says too many photos?! I'd say you've got the perfect ballance! In fact, don't be shy! Can never see too many photos on a build like this!

 

Very interesting!!!

[Craig855S]

That spigot, so much sexier than it needs to be

[HIGHTOWER]

That spigot, so much sexier than it needs to be

HAHAHA! I thought that! Was in awe when I saw it!

[blacksofstichill]

A genuine thank you for documenting your builds here. Giving enthusiasts a chance to see the processed that we wouldn't normally get a chance to.

 

You also look like you do things the right way, something that seems to be rare nowadays

 

Thanks, I really enjoy doing the work and documenting it as well, if other people enjoy seeing what has been done and it gives them some ideas then all the better.

 

 

I can only echo what others have said! These threads are fantastic? Who says too many photos?! I'd say you've got the perfect ballance! In fact, don't be shy! Can never see too many photos on a build like this!

 

Very interesting!!!

 

Many Thanks! I'm glad to hear you're finding these threads interesting, it's just a few people that have commented (not on here I might add) that they don't see the need for me to take photos of everything I do along the way such as painting bits and pieces, not to worry though, I'll not be changing my ways!

 

That spigot, so much sexier than it needs to be

 

Cheers! It's one of those things that takes "X" amount of time to make but just 1 extra minute spent on it can make it look so much better, I agree though, it doesn't need to be as shiny as I made it!

 

More updates, sorry for the delay, it's just finding the time to sit down and do this but here goes -

 

Masked off ready to be sprayed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0149.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0150.jpg

 

And spray painted with several coats of Simoniz Gloss Black Engine Enamel -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0151.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0152.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0153.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0154.jpg

 

With the masking tape removed it's looking pretty fresh and ready for the build to start -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0155.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0156.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0157.jpg

 

with the engine block all reworked it's onto the rebuild now, block flipped over ready for the crank to be fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0158.jpg

 

Normally I would never recommend re-fitting previously used bearing shells, however this engine had only covered a very low mileage since a rebuild and the shells in this were simply pristine with no sign of wear at all so they were cleaned and re-fitted in the same positions as they were removed from -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0159.jpg

 

Crankshaft Cleaned up and re-fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0160.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0161.jpg

 

Thrust Washers/bearings re-fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0162.jpg

 

Main Bearing Caps fitted with bearing shells -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0163.jpg

 

Main Bearing Caps fitted and torqued down -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0164.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0165.jpg

 

Arias Low Compression Forged Pistons and Cunningham Forged Rods all thoroughly cleaned up and they are like new, they look far too good to hide away inside the engine! -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0166.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0167.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0168.jpg

 

First Piston being fitted, clamp fitted to compress the piston rings and the piston is eased into the fresh new bores -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0169.jpg

 

No 1 Piston Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0170.jpg

 

No1 and No4 Piston Now fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0171.jpg

 

With No 2 and No 3 Pistons also fitted that's all 4 pistons fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0172.jpg

[Stu]

It's always nice when you have your freshly machined, cleaned and painted block ready!