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Escort RS2000 4x4 2.0 Turbo Conversion


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Some great fabrication work there. Nice to see the car being saved instead of the easy route of scrapping it, reminds me of the days i worked for a bodyshop specializing in restorations. You never know what your going to find until you start taking it apart. So i can appreciate and understand how it can sometimes seem never ending just as you think you've done all the welding you find something esle, but for me it was always the end result of seeing it finished and back to its former glory, and in most cases looking better than the day it was made. If there wasn't people that were prepared to put this much effort, time, blood sweat and tears into bringing cars back to life, where would most if them be.

 

I've got a x reg mk6 finesse which I've always said no matter what it takes i will make sure it never gets scrapped. Granted it easier for me as im in the body work trade. But someones got to keep these mk6 escorts on the road.

 

Keep up the good work look forward to the end result. :thumb:

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The mind boggles! Look at the state of that :jaw: 4x4 or otherwise its not worth saving that! Re shell and transfer everything to it!!! How the hell do the pillars rot by the door hinge for christsake!

 

Not to put a downer on it because you've done great work on it but the owner is a loony!

 

Look forward to the day we start seeing the end of this rot and more of the engine/finishing front. :thumb:

 

ive met the owner a few times lives just up the way from me....he really really likes rs2000s lol

 

Think he likes rust more! X(

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Yikes !!! :eek: :O

 

Scary eh?!

 

That is one rotten shell. When do we get to the juicy bits!?!

 

Juicy bit's to follow after the rot is dealt with....not long now!

 

Back on topic though, that is one hell of a lot of work you are putting in there!! I love all these update :thumb:

 

Cheers! :cheers:

 

The mind boggles! Look at the state of that :jaw: 4x4 or otherwise its not worth saving that! Re shell and transfer everything to it!!! How the hell do the pillars rot by the door hinge for christsake! Not to put a downer on it because you've done great work on it but the owner is a loony! Look forward to the day we start seeing the end of this rot and more of the engine/finishing front. :thumb:

 

To be honest we knew the scuttle panel below the windscreen was rotten before we started as he'd had the screen replaced and saw how bad it was at the time but had no way of sorting it there and then. Although it looks pretty horrific it's not that bad to sort really once the screen is out. The rot on the pillars is most likely down to water getting in between the skins of them from the holes in the scuttle. The rot is almost at an end though, don't worry! :cheers:

 

 

ive met the owner a few times lives just up the way from me....he really really likes rs2000s lol

 

He certainly does, he's had quite a few of them over the years including the Mountune powered ex max Power RS2000.

 

Some great fabrication work there. Nice to see the car being saved instead of the easy route of scrapping it, reminds me of the days i worked for a bodyshop specializing in restorations. You never know what your going to find until you start taking it apart. So i can appreciate and understand how it can sometimes seem never ending just as you think you've done all the welding you find something esle, but for me it was always the end result of seeing it finished and back to its former glory, and in most cases looking better than the day it was made. If there wasn't people that were prepared to put this much effort, time, blood sweat and tears into bringing cars back to life, where would most if them be. I've got a x reg mk6 finesse which I've always said no matter what it takes i will make sure it never gets scrapped. Granted it easier for me as im in the body work trade. But someones got to keep these mk6 escorts on the road. Keep up the good work look forward to the end result. :thumb:

 

Cheers for your kind comments, much appreciated. When I'm working on a project like this I concentrate on one area at a time so it doesn't seem like such a massive task all at once, I'm looking forward to getting it finished and looking back at what's all been done to it. :cheers:

 

 

Anyone know if the 4x4s where made separate from the 2wd rs2000s ? I have seen 4 of theses 4x4s that have been proper rotters

 

I don't think they were made in any different factories from the 2wds to be honest, maybe they just like to rot a little more!

 

Starting with the passenger side I cut the rotten area out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01364.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01365.jpg

 

First repair section made for the passenger side, quite an awkward shape -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01366.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01367.jpg

 

Second repair section made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01368.jpg

 

Trial fitted in place to see how they looked -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01369.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01370.jpg

 

First section seam welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01371.jpg

 

Second section also fitted and all of the welds dressed back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01372.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01373.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01374.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01375.jpg

 

Moving onto the drivers side now, it's a bit more awkward as this side still needs the bulkhead repaired below the scuttle panel and it's not like the passenger side wheere I could weld the underside with my head through thre battery tray -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01376.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01377.jpg

 

Rot cut out on the drivers side leaving a large hole -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01378.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01379.jpg

 

The plan here was to weld in the bulkhead sections first and weld them to the remaining front section of the existing scuttle from above, first section made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01380.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01381.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01382.jpg

 

Next section made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01383.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01384.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01385.jpg

 

 

 

Welds dressed back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01386.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01387.jpg

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what are these 4x4's like to drive?

 

i would have thought the 4wd system would sap quite a chunk of the power

 

I love the way a 4x4 drives, you tend to take it for granted just how well it grips until you jump back into a 2wd rs and find yourself wheelspinning and losing traction on damp roads in particular. Some people say the 4x4 is much slower but in reality it's much the same after the initial take off and once you're on the move it's the very same as a 2wd as far as how it pulls, etc. Driving a 2wd one hard can feel like it's quicker as it's a bit more "frantic" spinning wheels and drifting off line out of a bend, etc but the 4x4 just grips and goes round corners with such ease that you don't appreciate how fast you are going. It's well worth having a shot of one if you get a chance!

 

First repair section for below the windscreen made and fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01388.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01389.jpg

 

Next section made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01390.jpg

 

And fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01391.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01392.jpg

 

Welds dressed back -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01393.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01394.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01395.jpg

 

Here's how it looks after that, all solid under the screen now -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01396.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01397.jpg

 

All primed and seam sealed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01398.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01399.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01401.jpg

 

And finished in gloss black -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01402.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01403.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01404.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01405.jpg

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Thats some cracking work right there :thumb:

 

Cheers! :cheers:

 

whats the boot lid like on that pepper red one in the background?!?!?!

 

if u wanna sell it....ill try n twist ollies arm to bring it back with him when he collects the 4x4 haha

 

The Pepper red Mk6 isn't for breaking anyway but unfortunately it's a Cabriolet so the boot lid wouldn't be any use to you!

 

Before I started the welding below the windscreen we had the screen removed very carefully by National Windscreens with the intention of refitting it once the work was done. However, things didn't go to plan as we had hoped, although the screen came out in one piece the fitter did say it wasn't unusual for a screen to break during removal or refitting as it only took a small chip or flaw in the glass for it to crack......and that's what happened -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01406.jpg

 

It was left overnight ready to be fitted the next day but when I lookedwent round the next morning it had cracked right up the screen, I can only guess that the temperature change overnight was enough to make the crack run right up from where this small chip was on the inside of the screen -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01407.jpg

 

So with a new screen on Order it was time to start working on the engine bay to get the old engine out starting with the radiator, header tank, airbox, etc -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01408.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01409.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01410.jpg

 

Exhaust and driveshafts removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01411.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01412.jpg

 

Power steering Pump and pipes, etc removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01413.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01414.jpg

 

Engine crane ready to take the strain -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01415.jpg

 

There were no lifting eyes on the engine so I borrowed some from a spare engine I had -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01416.jpg

 

Engine on it's way up to lift it off the rear mount -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01417.jpg

 

And on it's way back down to the ground -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01418.jpg

 

Down on the ground and ready to be pulled out the front -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01419.jpg

 

Engine removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01420.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01421.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01422.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01423.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01424.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01425.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01426.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01427.jpg

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  • 2 weeks later...
It'll be nice to get your hands on the oily bits after all that welding! Nice update.

 

Cheers! It was certainly good to get the welding finished! :cheers:

 

 

whats goin to happen with the old engine now then?

 

The old engine is still with me, Olly would sell it if anyone was interested, if it doesn't sell I think we might end up doing another engine build with it though.

 

Next on the agenda was to clean up the engine bay and paint it, at the moment it was a combaination of original white primer and blue paint but we wanted it to be black -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01428.jpg

 

Starting off at the bulkhead area I cleaned up the repaired areas ready for priming and seam sealing -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01429.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01430.jpg

 

Bulkhead primed and sealed, engine bay degreased -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01431.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01432.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01433.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01434.jpg

 

Wiring Loom, Servo, etc all masked up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01435.jpg

 

First coat of primer -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01436.jpg

 

 

Bulkhead coated with stone chip -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01437.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01438.jpg

 

Bulkhead was primed and given it's first coat of black, the rest of the engine bay was also coated with stone chip with the exception of the slam panel -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01439.jpg

 

Whole engine bay coated in black -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01440.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01441.jpg

 

Rubbed down to smooth it all off a little -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01442.jpg

 

And all coated again in black to finish it off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01443.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01444.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01445.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01446.jpg

 

At this point the new screen arrived and was fitted without any hitches -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01447.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01448.jpg

 

Masking removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01449.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01450.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01451.jpg

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