Escort RS2000 4x4 2.0 Turbo Conversion

[blacksofstichill]

Have you had some time off? Your hands are cleaner than usual

 

Nah, it's just a trick of the light!

[blacksofstichill]

Onto the Transfer Box now, here it is as removed from the car -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01532.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01533.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01534.jpg

Opened up for inspection -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01535.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01536.jpg

The Planetary Gears were all in excellent condition as was everything else inside the box -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01537.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01538.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01539.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01540.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01541.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01542.jpg

All Parts degreased and ready for the rebuild -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01543.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01544.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01545.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01546.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01547.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01548.jpg

This little breather Pipe on the top of the box allows it to vent and also tends to spit out any excess oil if you run the box with a higher oil level than standard -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01549.jpg

Here it is from inside the casing, you can see that the inner part of the casing shrouds this vent area from the main part of the box -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01550.jpg


Here is the same area on the other half of the casing -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01551.jpg

Our intention is to run a higher than standard level of oil in the box, the recommended amount of oil is only 300ml but I'm aiming to run it with around 800ml of oil in it to ensure that the gears have adequate lubrication. To avoid that excess oil being thrown out of the breather pipe we'll run a pipe from the breather up to a Catch Tank with a vent on it. That way, any excess oil will run up into the tank momentarily and then run back into the box as the pressure inside it drops again.

Onto the rebuild of the box now -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01552.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01553.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01554.jpg

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01555.jpg

This bearing can either be fitted to the gear or the casing during assembly but I tend to fit it to the gear is it stays in place on it much easier -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01556.jpg

Both halfs of the casing loosely fitted together -

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01557.jpg

[scottybo]

Great as always

[blacksofstichill]

Great as always

 

Cheers, much appreciated!

 

With the bolts loosely fitted these dowels are used to locate the two halves of the casing correctly -

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01558.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01559.jpg

 

Drive for rear propshaft ready to be fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01560.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01561.jpg

 

All assembled and primed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01562.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01563.jpg

 

Basecoated in VW Metallic Grey -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01564.jpg

 

While that paint was drying I took some time to look at the stereo wiring in the car, it was a muddle of wires with bare ends, chopped wires, etc, etc and I wouldn't say it was safe to leave it like that -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01565.jpg

 

So, I removed everything that wasn't needed including a knackered tweeter that had been lurking somewhere around the dashboard -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01566.jpg

 

That leaves the standard Ford wiring and plugs with the loom retaped and an ISO adaptor loom fitted to to, depending on what stereo is fitted when the car is finished we may have to get another adaptor to suit, the one used with the current stereo had been chopped to bits, I'll solder it later rather than use connector blocks -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01567.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01568.jpg

 

Back to the transfer box to lacquer it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01569.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01570.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01571.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01572.jpg

 

Alternator fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01573.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01574.jpg

 

Power Steering Pump fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01575.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01576.jpg

 

[lee grout]

Nice update. Think you were right to sort all that dodgy wiring lol

[blacksofstichill]

Nice update. Think you were right to sort all that dodgy wiring lol

 

Cheers!

 

Now for the Turbo, CR Turbo's have done a fantastic job of bringing this Turbo back to life! -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01577.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01578.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01579.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01580.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01581.jpg

 

New Stainless Steel Gasket for the Turbo -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01582.jpg

 

Turbo fitted, it will have to be removed no doubt to sort out the oil return properly, etc but boy, am I happy to see this fitted! Love it! -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01583.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01584.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01585.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01586.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01587.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01588.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01589.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01590.jpg

 

with the Turbo bolted in place it was time to look at the oil return. I'd already fitted a spigot in the block previously -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01591.jpg

 

I also had the original return pipe -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01592.jpg

 

With the return pipe bolted to the turbo you can see they're not close in enough in line to join together with a hose -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01593.jpg

 

With a bit of cutting and welding I altered the angle to suit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01594.jpg

 

A coat of paint and it's ready to fit along with a new gasket -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01595.jpg

 

Bolted into place and connected using the original return hose -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01596.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01597.jpg

 

For the oil Feed I still had the original feed pipe and Adaptor for the Oil Switch -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01598.jpg

 

Cleaned up and fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01599.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01600.jpg

 

 

[sidrick]

Now we're talking! Fantastic work and attention to detail.

[scottybo]

My dad works next door to cr. They are about a mile away from my house. Good to know that you recomend their work in case i ever want anything doing in the future!

[shifty]

More good work.

Exhaust manifold looks smart, what was used for that finish?!

[lee grout]

What's happened to this then?? Any updates??

[blacksofstichill]

Now we're talking! Fantastic work and attention to detail.

 

Cheers!

 

My dad works next door to cr. They are about a mile away from my house. Good to know that you recomend their work in case i ever want anything doing in the future!

 

Yeah, they did a cracking job on this one, really brought it back from the dead!

 

More good work.

Exhaust manifold looks smart, what was used for that finish?!

 

Thanks, I used a Simoniz engine enamel on the manifold, I don't think it will stand the heat once it is used but it looks good for now!

 

What's happened to this then?? Any updates??

 

I haven't been on here for ages so have a lot to catch up on, the project is still on the go, here's some more updates for now -

 

Power Steering Feed Pipe fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01601.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01602.jpg

 

Original Coil Pack from the Car (Zetec Coil Pack Conversion) ready to be cleaned up and fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01603.jpg

 

Coil Pack Bracket -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01604.jpg

 

Cleaned back ready for painting -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01605.jpg

 

Primed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01606.jpg

 

Painted and fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01607.jpg

 

Coil Pack and Leads cleaned up and fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01608.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01609.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01610.jpg

 

Water Pipe Elbow as removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01611.jpg

 

Cleaned up and fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01612.jpg

 

Dipstick Tube as removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01613.jpg

 

Cleaned up, painted and fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01614.jpg

 

Water Pipe from Olly's stash, all Powder coated -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01615.jpg

 

Sadly not a straightforward fit on this engine as the Exhaust Manifold is in the way of where this would normally be fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01616.jpg

 

As you can see, the pipe is quite a distance away from where it neeeds to bolt onto the block -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01617.jpg

 

Offset Bracket made from Stainless Steel Sheet to connect the pipe to the hole on the block -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01618.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01619.jpg

 

Fitted to the engine, this bracket holds the water rail in the right position and still allows the original hose to the heater radiator to reach it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01620.jpg

 

Clearance all around the pipe -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01621.jpg

 

I needed a hose to join the pipe onto the elbow on the Block so I cut a piece of hose from a scrap MG ZR we had here -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01622.jpg

 

Fitted and clipped onto the dipstick tube to hold it in place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01623.jpg

 

Heater Matrix Hoses mocked into place to see how they look -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01624.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01625.jpg

 

Next up to sort out was a water feed to the turbo and a return from the Turbo to the radiator, I don't have the banjo bolts for these as yet but when I do they'll fit into the turbo here -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01626.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01627.jpg

 

With the Radiator trial fitted in place I had a look at where I could join it into the existing system -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01628.jpg

 

 

[scottybo]

surely you will be fitting a nice new shiny stainless rad or something?

[sidrick]

I thought you'd forgotten about us. Great work

[lee grout]

What Sid said. 

[stoo2000]

It's like artwork, I would hate to get it oily/dirty!