Escort RS2000 4x4 2.0 Turbo Conversion

[blacksofstichill]

with the throttle body now all test fitted and proven to work it was time to strip it all down and tidy it up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0636.jpg

 

Bare Throttle Body onto the Centre Lathe -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0637.jpg

 

Bore of throttle body, smoothed and polished -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0638.jpg

 

All other parts of throttle body cleaned up ready for painting -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0639.jpg

 

All primed and hung up to dry -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0640.jpg

 

All Painted, throttle body itself in Moondust Silver, all other parts in Satin Black -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0641.jpg

 

Onto the rebuild now -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0642.jpg

 

Idle Speed Control Valve needed a new Gasket as the original one was damaged when I stripped it down -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0643.jpg

 

New Gasket made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0644.jpg

 

ISCV re-fitted and that's the throttle body all complete again -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0645.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0646.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0647.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0648.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0649.jpg

 

New Throttle Body Gasket made, it looks squint but it's just the way I'm holding it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0650.jpg

 

And all fitted back onto the Plenum -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0651.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0652.jpg

 

ISCV is close to the Fan Switch but still has clearance for the plug to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0653.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0654.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0655.jpg

 

New Spark Plugs -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0656.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0657.jpg

[blacksofstichill]

With these fitted that's the engine now as complete as possible until I have the Turbo, etc here and until I get the original engine out of the car -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0658.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0659.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0660.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0661.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0662.jpg

 

I trial fitted the hose onto the thermostat housing to see how it looked. It is certainly close to the throttle cable bracket but won't foul on it or the throttle cable once fitted. I'll bracket/clamp it to the side of the head to be 100% sure it won't move and rub on the bracket or the cable though -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0663.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0664.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0665.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0666.jpg

[escortlew]

Such a fantastic build, keep up the epic work !

[sidrick]

Another job well done Now time to wash your hands

 

What's the next thread going to be about?

[blacksofstichill]

Such a fantastic build, keep up the epic work !

 

Thanks, much appreciated!

 

Another job well done Now time to wash your hands

 

What's the next thread going to be about?

 

Ah, but as one part of this job finishes another part starts so I don't need to wash my hands yet!

 

Unlike the last engine which was built up and handed over to the owner, this time I have the car here and have loads of work to do to it as well. Pics, etc will follow soon.

[lee grout]

Great update. The level of detail in this is awesome and it looks amazing. Cant wait to see the turbo bolted up

[blacksofstichill]

Great update. The level of detail in this is awesome and it looks amazing. Cant wait to see the turbo bolted up

 

Thanks, glad you're liking it!

 

With the engine well underway the car itself made it's way up to mine too, a 431 mile journey for Olly. This was back in January and we had quite a bit of snow up this way just to add to the fun!

 

Some of Olly's road trip pics -

 

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3310_zps32c4373d.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3312_zps1bb2a099.jpg

 

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3323_zps2ed16f57.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3324_zpsb18f1b0b.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3327_zpsacf230f7.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3329_zpsf8b5f6ac.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3331_zps820a1522.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3333_zpsf35e775a.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3334_zpsfc71f879.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3335_zpse9b60dfd.jpg

 

nearly there

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3338_zpsa27c3af5.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3340_zps827daa53.jpg

 

arrived at destination

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3339_zps05cd9929.jpg

 

trip counter

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3341_zpsb1c29234.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/rs2000/stichill_zpsb7fb4292.jpg

 

http://i579.photobucket.com/albums/ss237/doctorevil72/IMG_3347_zps8c892ebb.jpg

 

While he was here, Olly got to see the Pistons he'd bought all those years ago too!

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3345_zps8fb3f51c.jpg

 

BY THE POWER OF STICHILL!

 

http://i579.photobucket.com/albums/ss237/doctorevil72/stichil_zpsb0feccb3.jpg

 

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3348_zps8f266db5.jpg

and taxi home

 

http://i579.photobucket.com/albums/ss237/doctorevil72/roadtrip/IMG_3349_zps9a3bf718.jpg

[escortlew]

Quality pics "by the power of stichill" lmao!

[blacksofstichill]

Quality pics "by the power of stichill" lmao!

 

Cheers, Olly made up the photo with the lightning strikes on it, he watched He-man as a kid too!

[Hezz]

Pmsl "power of stichill"

[blacksofstichill]

With the engine now effectively complete for the moment it was time to move onto the car itself. Originally an Auralis Blue Mk6 4x4, Olly has already had the front end and sideskirts from a mk5 fitted, morretes fitted, etc and the car was resprayed in Gloss Black. The car itself has been at my place for a while now so it isn't as clean as it could be with being parked up for so long but I can see it will clean up very well -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0667.jpg

 

This is my favourite view, I think it looks really aggresive from the front -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0668.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0669.jpg

 

Back end is Standard Mk6 with the exception of the Accessory rear spoiler, half tint lights and smoothed ford badge recess -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0670.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0671.jpg

 

Under the Bonnet, this is the area that will see the biggest transformation in the weeks to come -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0672.jpg

 

Interior will be removed during the work to check for rot, etc -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0673.jpg

 

And in the boot there are some parts tucked away which will be fitted during the rebuild -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0674.jpg

 

Nice gap which will house an intercooler when I'm done -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0675.jpg

 

My plan of attack is to firstly go over the whole car checking for rust, do any welding that's required, make sure the car is strucurally sound and rustproof it all. With this in mind I started at the front and removed the Bumper, grill and lights -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0676.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0677.jpg

 

These are both common rot spots, both have already been plated but I'll clean it all back to make sure its solid before re-sealing them -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0678.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0679.jpg

 

I removed all the sealer/underseal from the front panel/crossmember to make sure it was solid. The first side was solid where the plates were but I did reveal a couple of rot spots around them -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0680.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0681.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0682.jpg

 

 

The other side was all good, only a couple of very small bits needing a spot of weld and the remains of the bonnet stop brackets from it's original front end which could do with being ground off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0683.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0684.jpg

 

Rotten section on Drivers side cut out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0685.jpg

 

A couple of small holes appeared between the original plated areas but these will be filled in with weld, the plates are sold at either side

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0686.jpg

 

Passenger side all cleaned up and still solid -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0687.jpg

 

Repair sections of sheet cut for the Drivers side -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0688.jpg

 

Out with the trusty MIG welder -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0689.jpg

 

First plate welded in to the front edge of the crossmember -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0690.jpg

 

Small plate welded in at the corner just below the headlight recess -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0691.jpg

 

Drivers Side all primed and resealed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0692.jpg

 

Passenger side all primed and resealed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0693.jpg

 

Both sides are now solid, I'll leave them in seam sealer for now but the slam panel will all be painted once the rest of the work is complete so it wil look a lot tidier than it currently does by the time I'm finished -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0694.jpg

[blacksofstichill]

with the front crossmember/front panel sorted out I moved onto the drivers side and started by removing the wheel and arch liner to see what was lurking behind it -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0695.jpg

 

After I'd checked out the nice big brakes, I was met with the very common site of a rotten inner wing rail -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0696.jpg

 

After some poking and prodding the true extent of it was revealed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0697.jpg

 

So, I cut out all of the rot from the outer section of the inner wing rail, which revealed that the inner section was also quite dodgy, particularly along the bottom edge -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0698.jpg

 

So, I cut out the rotten area back to solid metal on the inner side of the inner wing rail too which brought me back to good metal to weld to all around -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0699.jpg

 

Repair section made for the inner section of the rail, the nicks cut out of the bottom edge are just to allow me to give it the slight curve it required to fit the shape of the rail -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0700.jpg

 

Inner section of repair plate welded in, this was hard to photograph properly but this is it viewed looking upwards with my head against the brake disc, this now gives me a good solid lip of metal along the bottom edge to weld my outer repair section onto -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0701.jpg

 

Outer repair section cut and folded to shape -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0702.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0703.jpg

 

Viewed from the front looking upwards from the hole where the sidelight fits in, you can see it's now solid on the inside and outside -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0704.jpg

 

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0705.jpg

 

Next area to look at in my hunt for rot was here, this is the area on the underside of where the ABS ECU is mounted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0706.jpg

 

As suspected once I dressed it back with the grinder I found a couple of holes very quickly and the rest of that general area was quite flakey -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0707.jpg

 

Here it is viewed from under the bonnet -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0708.jpg

 

So, I cut a section out to get rid of the rust -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0709.jpg

 

I then made a repair section, it's shown as being flat here apart from one bend but it was formed into shape around the other edges once it was tacked into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0710.jpg

 

Repair section welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0711.jpg

 

Seam sealed under the bonnet -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0712.jpg

 

And also fully seam sealed on the areas I had welded on the inner wing -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0713.jpg

 

All of the seam sealed areas which will be visible once the car is complete (such as the inner wing area under the bonnet) will be smoothed and painted later, right now my primary concern is to do any welding required and seal it up to protect it from the elements.

I thought I might be finished working under the wing but sadly I found another spot needing some work -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0714.jpg

 

The extent of the rust was much worse than can be seen from inside the wing though, a quick look and some prodding underneath revealed a hole and some very scaley rust right around the subframe mounting -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0715.jpg

 

Because the rust is right around the subframe and leaves no solid metal around it to weld a plate to while the subframe is in place I dropped the subframe down on that side to give me some access and also to see how solid it was underneath the subframe itself -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0716.jpg

 

The metal which had been hidden by the subframe was still good. This area is double skinned, the area I wanted to replace forms the outer skin and the front edge of the floorpan sits quite closely behind it forming the inner skin. A look under the carpet revealed that the edge of the floor and inner arch skin was needing attention in the same area -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0717.jpg

 

So, I came up with a plan, instead of having to drop the front subframe completely to get access to cut out the rust and weld in the new plates, I decided to cut a section out of the floor pan/inner arch skin which was large enough to allow me access to cut the rust out from above and also to allow me to weld my new repair section to the good metal of the subframe mounting from inside the car as well as the areas I could access from underneath anyway. Excuse the roughness of the cutting, this will be tidied up before the new inner plate is welded in place, you can see though that there is good metal to weld to around the subframe mounts -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0718.jpg

 

I cut and folded up a repair section, this panel will give me something solid to weld other plates around it such as the infill panel on the inner sill side and the plate required to the front side above the subframe -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0719.jpg

 

I haven't got it fully welded at this stage but I've done enough to give you an idea of what I'm trying to achieve, once it's welded all round and the welds are dressed back it will look a lot better, here it is from underneath, it's welded on the underside to a thick (double skinned) area of floorplan and slipped into place above the subframe. More cutting and plating is required to the inner sill side as you can see here but the plate I've made gives me something to work from -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0720.jpg

 

On the inside of the car, the section I've cut out for access has allowed me to weld the plate to the existing good metal of the subframe mounting, it isn't fully welded and dressed at this stage but hopefully you can see what I'm intending to do, it will look a lot better than it does just now by the time it's finished -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/0721.jpg

[danj8608]

Ive ever had escorts rust on the chassis legs.. sills and rear arches. .new to me on this keep up the good work. I

[blacksofstichill]

Cheers! If you want to see some very common rust spots on these cars then you'll have to follow this thread, there's loads more rust still to come!

[lee grout]

Brilliant Love the look of this, mk5 front end that is. Looks mean as fook!

 

That is one mental journey to make! Why not have you build the engine and courier it down here though???