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Escort RS2000 4x4 2.0 Turbo Conversion


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Well...............................

 

1: Great work as ALWAYS.

 

2: Surely it would of been cheaper for the guy to find a clean shell for a couple hundred quid!? I bet your well into that sort of figure with repairs and I bet there's still plenty to go! 8o

 

Cheers! :cheers: It's quite difficult finding another 4x4 shell that's in good order that wouldn't need welding of some sort unfortunately. Another option would have been to have started with another complete car but again, to get a really good one he'd have had to spend quite a bit of cash too so it's not so easy with it being a 4x4.

 

 

Well...............................

 

1: Great work as ALWAYS.

 

2: Surely it would of been cheaper for the guy to find a clean shell for a couple hundred quid!? I bet your well into that sort of figure with repairs and I bet there's still plenty to go! 8o

 

Top top work, love following this.

 

Its a 4x4 isnt it, there would be limited numbers and at a premium price.

 

Thanks! :thumb: Yes, that's the problem, with it being a 4x4 it really reduces the chance of finding another shell. I've got another 4x4 here at the moment which is absolutely pristine on the outside, flawless outer bodywork, etc and underneath it is much worse than this one!

 

 

A really good read, good work, and loving all the pics

 

Cheers!

 

 

5 days without an update? Unacceptable!

 

I assume you're too busy cutting and welding though :P

 

Plenty of cutting and welding in this one! :cheers:

 

5 days without an update? Unacceptable!

 

I assume you're too busy cutting and welding though :P

 

i doubt there will be much original metal left by the end!

 

Yeah, plenty of new metal going into this, I think I used around 2.5 square metres of sheet from start to finish.

 

 

First repair section made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01026.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01027.jpg

 

Another repair section for the other side of the leg made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01028.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01029.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01030.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01031.jpg

 

Flat sheet cut for the bottom of the leg -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01032.jpg

 

Welded to my previous plates -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01033.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01034.jpg

 

I cut another flat piece of sheet to weld over the remaining area and that completes the repair of this part of the leg -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01035.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01036.jpg

 

Onto the next area needing attention -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01037.jpg

 

Rot cut out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01038.jpg

 

Repair section made -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01039.jpg

 

And welded into place -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01040.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01041.jpg

 

And the chassis leg is now solid -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01042.jpg

 

Priming and seam sealing the latest repairs -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01043.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01044.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01045.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01046.jpg

 

Earlier we had looked at this bit but wanted to wait until it was time to look at the sills -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01047.jpg

 

This side needs an outer sill, it's got rot over such a big area it's not worth plating individual areas. Luckily though the rot is mostly along the bottom, the top half of the sill is as good as new so I'll be able to join it below the line of the sideskirt -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01048.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01049.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01050.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01051.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01052.jpg

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  • 1 month later...

Before tackling the sill I still needed to bolt the rear subframe back up, etc and before I could do that I had some polybushes to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01053.jpg

 

Starting with the easiest ones of the lot I removed these arms to fit the new bushes -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01054.jpg

 

The old and the new -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01055.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01056.jpg

 

These bushes were the next ones to be removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01057.jpg

 

And they're out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01058.jpg

 

While I was working in this area I remembered that I'd have to alter the backing plate for the disc -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01059.jpg

 

Existing discs on the left, discs to be fitted on the right -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01060.jpg

 

Edge of backing plate cut off to allow room for the larger disc -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01061.jpg

 

Still to take the sharp edge off but that's the rough of it cut off -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01062.jpg

 

Old bushes versus new bushes -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01063.jpg

 

Normally I would fit the new bushes into this while its in place on the car using a Hydraulic clamp but the hub would have to be removed later anyway as you'll see further on in the thread -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01064.jpg

 

Rear tie rods all needed to be unbolted for rebushing -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01065.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01066.jpg

 

Same goes for the anti roll bar bushes -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01067.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01068.jpg

 

Adjustable rear link arm to the back of the diff has eccentric washers to allow adjustment of the rear toe in/out, these were all seized solid -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01069.jpg

 

The nut sheared off on the opposite side but this one was okay, you can see the eccentric washer -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01070.jpg

 

Diff mount bushes need to be changed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01071.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01072.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01073.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01074.jpg

 

Eccentric bolt just clears the driveshaft when the diff is removed from it's subframe mounts and pushed as far up as it can go -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01075.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01076.jpg

 

Brake bias valve linkage unbolted from the front rods -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01077.jpg

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These long bolts simply would not budge, I could see they would shear off before they ever moved and heating them in place on the car wasn't handy -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01078.jpg

 

On the same side there was also a split in a driveshaft boot -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01079.jpg

 

So, I removed everything in one piece so I could heat the bolt in the workshop to remove it and also so I could change the driveshaft boots -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01080.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01081.jpg

 

 

I also removed the other side too as it had also sezied -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01082.jpg

 

Both sides ready to take round to the workshop -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01083.jpg

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Great work, great update!

 

I still think you're mental for taking on something that rusty :roll:

 

Cheers, being a bit mental always helps! :cheers:

 

 

Great work, great update!

 

I still think you're mental for taking on something that rusty :roll:

 

if someones paying then i guess work is work

 

i want you to work on my engine!......have to get saving

 

Cheers, I could do with another engine build project once the enigne for this is off the stand! :thumb:

 

 

excellent work as usual. Just a shame theres soooooooo much rust to battle before we start seeing some forward progress.

 

Thanks, yes, there's certainly plenty of rust but it's going to be a very soldi car once it's finished. :cheers:

 

Great dedication, 4X4 so not just any old Escort either.

 

Look forward to the next update.

 

Thanks, it's a lot of work but it is worth it to save the car and build it into something special. :thumb:

 

Since I had all of the items removed that needed re-bushing I made a start on these with the rear diff mounts, unfortunately I had sheared a bolt off when I removed this one -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01084.jpg

 

Luckily though it came out without too much trouble using a pair of vise grips, it must have just been weak rather than excessively tight -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01085.jpg

 

Onto the hydraulic press to remove the old bushes -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01086.jpg

 

Old bushes out and bush housings cleaned up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01087.jpg

 

The new bushes for these are a 2-piece fitting so are easily fitted into the housings by hand -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01088.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01089.jpg

 

Because I was about to start rebuilding the rear end of the car it was now time to also look at the new suspension being fitted. This lovely box from Spax contains a prototype set of RSX Coilovers, I've been dying to get this opened and fit them but had to wait until the rest of the car was ready -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01090.jpg

 

They even sent a nice Baseball Cap too! -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01091.jpg

 

This rear unit was already built up in the box but only loosely built for them to see that everything fitted together, it still has to come to bits to fit a 3-bolt top mount instead of the 2 bolt one fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01092.jpg

 

Correct fitting at the bottom for a 4x4 -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01093.jpg

 

Compared to the existing rear unit you can see that visually it looks spot on for fitment -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01094.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01095.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01096.jpg

 

Before I could bolt anything up at the back end of the car I needed to give all of the chassis legs a good coating to protect them from the elements in the future. The whole car will be waxoyled at the end with Schutz used beforehand on repaired/rust prone areas but at this stage I just needed to coat the areas which would be obscured by the rear subframe once it bolted up, I also coated some of my other repairs at the back end while I was at it-

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01097.jpg

 

Repaired areas coated with Schutz -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01098.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01099.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01100.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01101.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01102.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01103.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01104.jpg

 

Both rear hubs and link arms seperated after some serious heat was applied to get the long bolt out in one piece -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01105.jpg

 

You can see how it siezes when it's as long as it is and has probably never been out since the car was new -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01106.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01107.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01108.jpg

 

Link arms onto the press to remove the old bushes -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01109.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01110.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01111.jpg

 

All bushes removed and new ones ready to fit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01112.jpg

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New bushes being pressed in -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01113.jpg

 

New bushes fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01114.jpg

 

All apart from 2 of them -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01115.jpg

 

These holes for the inner bushes at the rear of the diff were larger than the other holes but the bushes suppied were all of the smaller size, the hole was approximately 2mm larger from memory -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01116.jpg

 

Not to be held back, I hatched a plan! I measured up and decided I could use the outer casing of the old bush to make up a spacer which would make up the difference in diameter -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01117.jpg

 

Centre of old bush pressed out -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01118.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01119.jpg

 

New bush fitted into old casing, the fit was spot on -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01120.jpg

 

And pressed into the arm -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01121.jpg

 

And that's all of the link arms done! -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01122.jpg

 

Next up was the bushes on the rear hubs -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01123.jpg

 

These were easily fitted in the vice to squeeze them in -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01124.jpg

 

Fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01125.jpg

 

Next job was to replace the damaged rear driveshaft boots -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01126.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01127.jpg

 

Old Boots removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01128.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01129.jpg

 

New boots fitted, I used QH "Stretchy" boots which can be fitted using a stretching tool which allows the boot to slip over the cv joints without seperating the joint from the shaft. The boots are "universal" hence why they aren't clipped in exactly the same place as the original ones -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01130.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01131.jpg

 

Next thing to do was make a new eccentric bolt to replace the sheared one -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01132.jpg

 

The plan was to fit the old washers to a new bolt -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01133.jpg

 

Original washer removed from the old bolt head -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01134.jpg

 

And welded to the new one -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01135.jpg

 

Welds dressed back and groove cut in the thread for the second eccentric washer -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01136.jpg

 

Front link arm bolted up with plenty of copper grease on the bolts -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01137.jpg

 

Rear link arm mounting point in subframe cleaned up and copper greased -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01138.jpg

 

And fitted, everything is buried in copper grease, they can be adjusted easily and hopefully the grease will prevent them from seizing again -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01139.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01140.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01141.jpg

 

The long bolt which had seized earlier was cleaned up and the hub, bush holes and bolt were all coated in copper grease before assembly -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01142.jpg

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Just out of interest. Is it possible to convert to 4wd using the parts from an rs4x4 on something like a gti for example

 

Yes, it's certainly possible to use the entire transmission, etc from a 4x4 but there's a lot of work involved in it I'd say and there's more to it other than the transmission itself. The likes of the petrol tank and exhaust too are also different and need to be changed amongst other things.

 

 

This thread is one of the best i've read on here just hope the updates keep coming.

 

Cheers, much appreciated! :cheers:

 

that's pity you didnt colored every part of this setup :/

 

I would have loved to have been able to paint the entire rear end setup on this but you have to remember that it's not my car and I'm working on this for a customer who's paying me to do so. As much as it would have looked great to have painted all of that we had to be realistic about the extra time and cost of doing that and it just couldn't be justified unfortunately.

 

More updates on this, Rear diff mounts re-fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01143.jpg

 

Rear anti-roll bar bushes fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01144.jpg

 

With both sides of the rear suspension now mostly built back up that was it ready for the rear struts -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01145.jpg

 

Old rear unit onto the spring compressor which allowed me to remove the top mount -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01146.jpg

 

Rear coilover fitted with 4x4 top mount and ready to fit to the car -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01147.jpg

 

And fitted to the car, fitting was perfect, no issues at all. As far as height adjustment goes, I left it at the setting Spax had put it at when they built this first unit -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01148.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01149.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01150.jpg

 

Rear arms re-fitted -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01151.jpg

 

And that's all of the rear suspension re-fitted and the rear subframe bolted back up to the chassis -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01152.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01153.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01154.jpg

 

Now it's time for the brakes to be fitted to the rear, both of these big rear discs had surface rust but nothing serious, from memory I think they are 320mm diameter, quite a bit bigger than standard -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01155.jpg

 

Calipers with brackets which came with the discs -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01156.jpg

 

The discs cleaned up very well -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01157.jpg

 

Shoes adjusted to the new disc/drum and copper greased on the moving parts, backing plates also straightened out and sharp edges removed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01158.jpg

 

Original Calipers along with "Big Disc" calipers and brackets, etc before a clean up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01159.jpg

 

Existing calipers were in good order so they will be re-used along with the caliper brackets from the other calipers, here they are after a clean up -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01160.jpg

 

Rear Disc primed and painted in gloss black and fitted to the car -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01161.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01162.jpg

 

Calipers primed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01163.jpg

 

Brackets primed -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01164.jpg

 

Brackets painted in gloss black -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01165.jpg

 

Caliper given one coat of gloss black -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01166.jpg

 

Then the brackets were fitted and they were given 2 more coats -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01167.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01168.jpg

 

Calipers fitted, no flexi hoses at this stage as we are waiting on braided ones being delivered but that's the rear brakes complete other than that -

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01169.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01170.jpg

 

http://blackengineering.co.uk/images/Doctor-Evil-RS2000-Turbo-Engine-Rebuild/01171.jpg

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