Escort RS2000 4x4 2.0 Turbo Conversion

[blacksofstichill]

With one bolt holding it in place it looks like it fits a treat, but that's just an illusion as it doesn't fit straight on at all -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0522.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0523.jpg

 

3 out of 4 of the holes line up but the throttle body overlaps the plenum flange at the bottom -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0524.jpg

 

The 4th hole as seen here is offset on the plenum and where the hole on the throttle body is there isn't any material to drill and tap into the plenum flange -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0525.jpg

 

I know a few people have fitted these Throttle Bodies before but I've never seen any detailed pics of how it was done, I'm guessing most have handed it all over to an engineering firm and picked it up once it's been welded, machined, drilled and tapped, etc and nobody gets to see the amount of work involved in fitting it.

 

Since I don't have a TIG welder or Alloy mig wire I couldn't weld it here myself, but in the interests of doing everything in-house I decided to make an adaptor plate instead which could be bolted on, so I started off with this, a piece of Aluminium plate -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0526.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0527.jpg

 

Into the milling machine to get machined to width -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0528.jpg

 

Then into the saw to be cut to length -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0529.jpg

 

Then back into the milling machine to be machined to length -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0530.jpg

 

All machined to the rough outer dimensions -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0531.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0532.jpg

 

Holes marked out and drilled -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0533.jpg

 

3 of them are clearance holes for the bolts to pass through and into the plenum, the 4th hole is tapped for the throttle body to bolt directly to the adaptor plate -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0534.jpg

 

Here you can see how the plate lines up with the plenum flange -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0535.jpg

 

And after some milling and filing I gradually get the plate to match up with the shape of the throttle body and the plenum flange -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0536.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0537.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0538.jpg

 

Getting there -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0539.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0540.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0541.jpg

 

Hole drilled in the corner for the adaptor plate to bolt into the offset hole in the plenum flange -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0542.jpg

 

With a small countersink in the hole I used a countersunk screw with a machined head to hold the adaptor plate in place accurately while the rest of the work was done on it, this meant that every time I took the plate off to do something I could refit it in pretty much exactly the same place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0543.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0544.jpg

 

Bolted to the plenum flange to see what needs to be trimmed in the top left corner -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0545.jpg

 

After some filing, the top left corner of the plate was taking shape -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0546.jpg

 

The plate now has it's basic outer profile matched up to the throttle body and the plenum flange -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0547.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0548.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0549.jpg

[Stu]

May have missed it earlier in the thread, but why did you ditch the OE TB and go to this hassle?

[blacksofstichill]

Great update as usual.

 

Cheers!

 

 

May have missed it earlier in the thread, but why did you ditch the OE TB and go to this hassle?

 

I didn't really explain the reasons for it so you're quite right to ask. Looking at previous Turbo conversions on this engine using the standard throttle body, most experienced problems with the Idle control valve which is normally mounted on the standard airbox, or connected to the induction pipe if a cone filter is fitted. They found that boost pressure leaked through it (this is only what I've been told)and some people removed it altogether (putting up with an erratic idle at times) to eliminate this. I think there would be other ways to overcome this but the Cosworth Throttle body came up at a favourable price so I never looked into it any further.

 

Some other conversions used this Throttle Body as it has an integrated Idle Control Valve to overcome this problem and it seems to do the job well. There's a lot of work in fitting it as you'll see but it should avoid potential problems in the long run.

[Stu]

Thanks for the clarification.

[blacksofstichill]

No problems

[blacksofstichill]

Centre hole marked out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0550.jpg

 

Centre hole pilot drilled and the plate is centralised around the hole in the 4 jaw chuck on the lathe -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0551.jpg

 

Centre hole bored out to match the diameter of the new Throttle Body -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0552.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0553.jpg

 

After some smoothing of my filing and a little tidying up, the adaptor plate is almost complete -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0554.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0555.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0556.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0557.jpg

 

Fitted to the throttle body to see how it looks -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0558.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0559.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0560.jpg

 

After all this it was trial fitted to see how it would work, you can see that the centre hole in the plenum flange needs quite a bit of material to be removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0561.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0562.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0563.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0564.jpg

 

Throttle Body trial fitted and at this point I can see the adaptor plate will do the job nicely -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0565.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0566.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0567.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0568.jpg

[sidrick]

The care and professionalism you put into your work is outstanding.

[blacksofstichill]

Thanks for that, much appreciated! I really enjoy doing the work and it makes all the difference.

[lee grout]

One word EPIC

 

 

Will you have to use some sort of gasket either side of that plate?

[scottybo]

is the rs2k inlet all good for turbo applications then?

[blacksofstichill]

One word EPIC

 

 

Will you have to use some sort of gasket either side of that plate?

 

Cheers! Yes, I made gaskets up for both sides to suit as you'll see in a bit once I've added some more updates on here.

 

 

is the rs2k inlet all good for turbo applications then?

 

Yeah, it's been done a few times before and seems to work okay, ideally a bespoke manifold would be better but for the power level we're aiming for this one will do fine.

 

Another update on this and it's back to the Plenum, as you could see it needed a bit of material removing to open it up to match the throttle body and adaptor plate -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0569.jpg

 

After some work with the Die Grinder and some smoothing out it looked like this -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0570.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0571.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0572.jpg

 

With that sorted out, Olly also wanted the top of the plenum to be smoothed out with the lettering removed, so it went from this -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0573.jpg

 

And after some work with a flap disc on the grinder it looked like this -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0574.jpg

 

And some sanding down to smooth it off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0575.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0576.jpg

 

Rubbed down, masked up and ready to paint -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0577.jpg

 

Primed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0578.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0579.jpg

 

Painted in Satin Black (still wet and glossy at this point) -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0580.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0581.jpg

 

While that was drying it was time to get back onto the inlet manifold -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0582.jpg

 

Instead of running the crankcase pipework into the inlet via a one way valve as it was originally, I'm going to run the vent pipework back into the air intake so this valve can be removed from the manifold -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0583.jpg

 

And to blank it off, a 10mm dowel fits in perfectly -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0584.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0585.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0586.jpg

 

Manifold cleaned up, masked and ready for paint -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0587.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0588.jpg

 

Primed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0589.jpg

 

Painted in Moondust Silver basecoat and lacquered -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0590.jpg

 

Masking removed and ready for the rebuild -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0591.jpg

 

Injectors cleaned up and ready to re-fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0592.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0593.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0594.jpg

 

Fuel Rail Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0595.jpg

 

Inlet Studs and Insulator Plate fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0596.jpg

 

Inlet Manifold fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0597.jpg

[blacksofstichill]

Plenum Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0598.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0599.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0600.jpg

 

Starting to really come together now -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0601.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0602.jpg

 

Throttle Body Gasket altered to suit the new hole size in the plenum -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0603.jpg

 

Adaptor plate painted in Silver Engine Enamel -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0604.jpg

 

Adaptor plate fitted to the plenum -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0605.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0606.jpg

[Forest]

top work fella!!! if only i had the skill and patients to do what your doing.

[Stu]

[blacksofstichill]

Thanks everyone for the positive comments so far!

With the adaptor plate made up it was time to then look at how the throttle cable could be fitted to the new Throttle Body, the fitting for the inner cable is different on the Cosworth one and the linkage for it is also on the opposite side to the RS2000 one -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0607.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0608.jpg

 

So, I decided to use parts of the RS2000 Throttle Linkage to adapt the Cosworth one so it would retain the standard cable -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0609.jpg

 

This is the part of the RS2000 linkage I wanted to use -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0610.jpg

 

But, I only needed a bit of it so I cut it down to suit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0611.jpg

 

You can see roughly what my plan is here, this is where I roughly wanted to join the RS2000 linkage piece onto the Cosworth one -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0612.jpg

 

Cosworth Linkage removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0613.jpg

 

And Cut back to suit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0614.jpg

 

With both linkages cut to suit, you can see where I'm going to join them together -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0615.jpg

 

All welded up into one piece -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0616.jpg

 

And trial fitted onto the Throttle Body -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0617.jpg

 

Trial fitted onto the Plenum to check everything still has clearance -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0618.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0619.jpg

 

Throttle Closed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0620.jpg

 

Wide open Throttle -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0621.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0622.jpg

 

Now that I'm happy with how the inner cable is fixed I then moved on to the outer cable fixing, this is the Standard RS2000 bracket but I didn't have anything like that for the Cosworth throttle body -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0623.jpg

 

So, I decided I would re-use this bracket and adapt it to fit the Cosworth Throttle Body, 2 of the holes already were at the right centres but other than this it wasn't close to fitting. The bracket fouled on the throttle body due to it being a different shape, the 3rd fixing hole wasn't possible to use at all and the bracket was opposite handed to what I needed. For starters I cut off the 3rd fixing which wasn't required -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0624.jpg

 

Then I cut back the middle section of the bracket so it cleared the shape of the Throttle Body -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0625.jpg

 

A quick trial fit, the bracket now fits onto the Throttle Body without fouling on it but as you can see, the cable fixing is at the top rather than the bottom so it won't work if it was left like that -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0626.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0627.jpg

 

More metal surgery required! I cut off the outer cable fixing section, apologies if this all looks a bit rough at this stage -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0628.jpg

 

With this part cut off from the bracket I folded it inside out so it would line up with the bracket in the right areas to give me a good are to weld the two parts together again, here it is held in place to see how it looked -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0629.jpg

 

And here it is after being welded together -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0630.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0631.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0632.jpg

 

Bolted back onto the throttle body to see how it all looks -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0633.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0634.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0635.jpg

 

When I adapted the linkage and altered the bracket I was careful to keep the distance between the outer and inner cable fixings the same as standard so it allows for the same amount of outer cable adjustment as it would on a standard car. I also trial fitted the throttle body and bracket by connecting it to a cable on another car to be sure it worked without jamming in any way and also to see that it was getting full throttle, etc.