Ford Czech Escort mk4

mariS_ZTi · 13-01-11, 09:46

Hello guys,

My name is Jan and I'm from Czech republic. I would like to present my car but I don't speak Romanian. Hope that It won't be a big problem. My wife come from Romania but it's not so easy to learn to speak. Ok.. let's start about my car.
It's 1987 Escort RS Turbo. I own it since 2003 and I spent a lot of money and time to rebuild it like I want.
Now It has unfinished wide bodykit made by me with clear lights. The engine was 1,6 turbo with 132Hp, now It's a Zetec 1.8 16v with 130Hp but I'm building the same Zetec with turbo and supposed power about 220Hp. Suspension is Koni sport with stiffness adjustable and lowering springs -30/-30. Brake system is in progress but It will be 324mm front brake discs with Porsche 4pot calipers and 280mm discs with RS2000 2 pot calipers and spot hand brake calipers on the rear. It stands on JSM Autosport 16" wheels (looks like OZ Racing Monte Carlo for Escort Cosworth) but I'm solving 17" with the same design. More informations are in my thread at british passionford forum here: http://www.passionford.com/forum/res...0-08-30-a.html

If You want to see or know some details ask me. I have a lot of pics. Hope You like it.

Cheers
mariS

sfert · 13-01-11, 14:26

Good project , not sure about the headlights , i was watching you on passionford to

) , keep up the good work and welcome to the site .

UNLORD · 13-01-11, 17:43

Big ups for the project ! looks very good! .... just one thing, get rid of the headlights!

mariS_ZTi · 13-01-11, 22:03

Thanks guys for the comments. I don't like the headlights too but I don't like the original lights more then these

I'm thinking about repaint inners of the lights in black colour or black chrome and these lights has the same shape like originals.

I'm thinking about making my own headlights but the first I want is finishing of the turboengine and the brake system.

mojoOOo · 14-01-11, 10:34

Nice car.I love escort mk4 in special rs turbo and xr3i.

**NWZeu** · 14-01-11, 17:31

Hello Jan, as i said before welcome to 4tuning forum. Posting in english is ok and the guys will follow the thread, i will make from time to time translations in romanian for everyone to understand.

Returning to the subject in case .... you car

..... what can i say ..... very interesting project. From the technical point of view, the braking system is very wise chosen, i've seen some projects that use those Porsche calipers on the front, also those RS2000 on the back and they will make a "good team".
Regarding the engine ....please make a presentation, don't hesitate to give details

about the actual specs and mods ...
Roll-cage ... very good option!
Design .... well, i'm not a fan of fatty cars

OEM and LOW are better for me ... but in the end if it will look good, what the hell

. Those headlights must go ... and those aftermarket tail lights are from an E30 (they are looking damn similar) ? Some "minor" but important little thing like the side mirrors, bonnet vents are bringing a nice touch to the line of the car.

In the end - nice project, you've sure got my attention

Salut Jan, dupa cum am spus si anterior, bun venit pe forum. Scrierea mesajelor in engleza este ok, cei interesati iti vor urmari topicul. Din cand in cand voi face traduceri in romana pentru ca toata lumea sa inteleaga.
Revenind la masina, ce pot spune, un proiect foarte interesant. Din punct de vedere tehnic, sistemul de franare este intelept ales. Am mai vazut cateva proiecte care foloseau aceeasi etrieri Porsche pe fata, deasemeni etrierii de pe RS2000 vor face o pereche buna cu cele de pe fata.
Legat de motor, fa te rog o prezentare si nu ezita sa dai detalii referitoare la specificatiile si modificarile actuale.
Roll-cageul ... o alegere foarte buna.
Aspect .... ei bine nu sunt adept al masinilor "umflate", joasa si kit de fabrica pentru mine reprezinta o alegere mai buna, insa daca la sfarsit va arata bine si asa .... atunci de ce nu. Farurile ar cam trebui sa dispara iar acele stopuri aftermarket .... seamana izbitor cu cele de pe E30. Cateva detalii "minore" precum oglinzile, prizele de pe capota, aduc o nota placuta liniei masinii.
Concluzie: un proiect frumos care cu siguranta mi-a captat atentia!

Ca rugaminte ..... dupa ce postati in engleza scrieti si in romana, macar ideea de baza sa ramana daca sunt ceva notiuni tehnice, poate avem useri ce nu se descurca cu limba engleza si sa se inteleaga materialul!

cozmin23 · 14-01-11, 17:57

nice car....i don't like the headlights and the taillights but the rest is very good...what color it will be in the end?

frumoasa masina...nu imi plac farurile si stopurile dar restul e frumos...ce culoare va fin in final?

teknologic · 15-01-11, 13:56

not a big fan of "in your face" body kits, but i do apprechiate your hard work. i'm more of a retro entuziast when it comes to looks... i'm curently building a ZT for my mk2 fez. didn't go through your whole thread on PF, are those vernier pulleys bought or "home made"? did you went for decomp pistons aftermarket valve springs and all the expensive bits?

PS
would like to know what intercooler you bought, i saw the pics on PF and i think it would do just fine for me as it's a bit hard to find an intercooler that fits between the radiator and the front panel of my fiesta. any chanse i could get some dimensions and info abought it?

cheers!

mariS_ZTi · 16-01-11, 21:29

Thanks guys or the comments.

I was starting to build the car after The fast and The Furious movie so I want a fat car with wide wheels with unique look. Now I know that the original look of the car is classic but I still want something different. And the original headlights don't shine as good as the cear ones. I want to build my own lights in the future but more important to me now is finishing the engine with turbo and finishing the bodyworks and interior. Bonnet vents are original from RS Turbo but my original bonnet was damaged so I put the vents to usual bonnet. It looks good and its functional.

The brake system is long story. First setup was original full overhal. Next step was getting front Porsche 944 turbo calipers and Focus ST170 discs (300mm). After it I boght Focus RS (324mm) discs but the calipers needs to widen for these discs because ST170 and RS has different width of the discs. It's not finished. Rear brakes was replaced by discs brake setup from Ford Sierra.. 253mm simple discs and 1 pot caliper with handbrake system. Hand brake cable is from Escort RS2000. These rear brakes was pretty small behind the rear big wheels (I had a 10x17" Keskin KT-1 wheels on the rear and 8,5x17 on the front) I get bigger rear discs from Focus ST170 (280mm) but I sill didn't lke the rear calipers. So I find that Escort RS2000 has 2pot calipers on the rear and It looks really good with front 4 pots. Like Subaru Impreza. In this time my mate gave me his front new Mondeo 280 drilled discs so I rebuild the rear calipers for wider discs. Problem was tat these rear calipers hasn't hand brake mechanism. I bought compbrake mechanical spot calipers for hand brake and the rear setup is complete: 280mm vented and drilled discs + widen RS2000 2pot calipers + mechanical hand brake spot calipers compbrake.. On the front will be 324mm Focus RS drilled and grooved EBC discs and widen Porsche 4pot calipers. Next problem with the brake setup is bad ratio of brake power. I get the wilwood proportioning valves for accurate setting up of the brake power. This brake setup is similar like for the race cars.

Something about Zetec Turbo engine:
When I bought the car it has classic CVH engine 1,6 with 8 valves, garrett T3 turbo and mechanical fuel injection. Original RS Turbo engine. This engine was bad from the beggining so I try to rebuild the original engine with no interferences to the inner parts. It wasn't so good idea and the engine was demaged. I start to find what type of engine is possible to get to the car and I find that the 130hp 1,8 16v Zetec is pretty easy to implant to the car and that it's not so big problem to turbocharge it. I find pretty good engine with low mileage and I put it into the car. It was in time when me and my mate bought about 5 pcs of RS Turbo cars in bad conditions but wit lot of spare parts for rebuilding. So I had the zetec engine and garrett T3 at the same time in the same place. I wanted to build the engine better then the CVH before but It's pretty expensive to buy pistons and lot of parts for building strong and powerfull zetec turbo engine so I bought another one for rebuild. I want to get about 200Hp and It doesn't need to change the internals. Turbo engine needs different compresion ratio so I change it with decompression plate and two custom build head gaskets. Inlet manifold was rebuild from MFi XR3 version because I like the shape of it. It was modified for connecting Fiesta RS Turbo EFi throttle body, EFi injectors and EFi fuel rail. I made a spacer plate for fitting the inlet manifold to the zetec head. Exhaust manifold is made by me and the vernier pulleys too. Ok.. the flanges for the exhaust were laser cutter by company and the vernier pulleys was made by my lathe operator (miller) but It's designed by me like many parts on my car

Intercooler is used from Avia (It's a Czech truck). It has pretty good shape, It's working and It costs about 70-80€. Next parts I have prepared for the engine is brand new iridium plugs with cables, brand new belt and pulleys, water pump, HKS SSQV blow off valve. Intake, rocker cover and fuel rail are black wrinkle coat painted. The engine is still out the car and I need to get some other parts: alloy rad because the IC has one outlet in the same place like original radiator. So the full alloy rad will be modified specially for my car. Next part I need is fuel pressure regulator and some pipes and hoses for connecting. These parts I will be buying first because I want to get the engine to the car this year as soon as possible.

Exhaust system is 2,5" pipe with no catalyst and Sebring Hot Steel back box with 4" outward rolled tail pipe. It sounds like WRC car.

Most important part is management. I bought fully programable MegaSquirt control unit with 3bar mapsenzor, wideband O2 senzor for mapping the unit, uprated beige injectors usedable to 220 Hp. I had the complete Efi management from Fiesta Turbo with cables and senzors but the control unit will be changed by MSQ one.

I want to build low cost zetec turbo but I spent a lot of money now. If it will be working fine I will made the second engine with decomp pistons and other expensive parts.

Gearbox is original from Turbo with limited slip diff.

Please don't talk about the headlights. I know that these don't look abslutely amazing and I'm thinking about changing them. It looks like tinfoil from bonbonniere but it's not important now. I will paint them black for the momment and I'll be thinking about build my own. Rears are aftermarket for BMW E30 and it looks pretty good. One day I will change the original back maybe.

Roll cage is bullshit now. It's build by me but I know that is bad. I don't know if I have to build real function rollcage or get the car with no one. It's illegal in our country and It's one of the worst things what officers don't like. I would like to use the car on the street so I don't tease the cops. But for the racing on circuit will be better to get the cage in. Maybe I will build folding cage what I can get out for the streets and get in for the racing and show days.

Hope that You find Your answers. If not ask me. And if You want to see more pics check my original Czech forum topic: http://www.fordfans.cz/phpbb3/viewto...=12172&start=0

Next time I will post some pics for You.

12cim · 17-01-11, 10:09

Hey Jan, i was hoping to get an answer about the oil pipes leading to the turbo and back.
Cheers mate!

Я7B. · 17-01-11, 10:55

Best Escort mk4 i ever see . Keep the good work and luck with your project .

mariS_ZTi · 17-01-11, 12:26

to 12cim:
Sorry mate, I forget it

The oil leading is from the back side of the engine to the turbo. It's the same like RS Turbo CVH engine and the same oil braided hose. Check the stainless steel braided hose on the pic, I hadn't my own pic. There is an oil pressure switch.

This hose is going to the turbo and from the bottom of the turbo there is a pipe going back to the engine. I have welded an intake part on the oil sump for connecting the pipe from turbo and the oil sump by hose. It's absolutely same like CVH RS Turbo engine but CVH has this inlet pipe insert in the block and not in the sump. It's not so difficult thing in turboing NA engine.

For better cooling the turbo is possible to get the oil cooler between engine and turbo. I will be using small OC fitted in front of gearbox for it.

mariS_ZTi · 17-01-11, 14:33

Here are some more interesting pics:
with Keskins KT-1 wheels

CVH engine

exhaust manifold

IC:

Dashboard with gauges (air/fuel ratio, oil temp and pressure, voltmeter, boost and escort mk7 dials):

MegaSquirt and Wideband O2 senzor:

Stainless steel decompresion plate and 0,75mm head gaskets:

Vernier pulleys:

Flange for fitting CVH intake to Zetec head:

Intake with welded flange for Fieste RS Turbo throttle body and Efi injectors:

HKS SSQV Blowoff valve:

**NWZeu** · 17-01-11, 19:27

That solution for the exhaust manifold i've seen it on 2.0 Mivec (Mitsu'), on C20LET an so on ...
Interesting option for turbocharghing that engine, i was on the brink to do this step also, but on a Duratec engine with a kit provided by focussport, but after some research i've concluded it isn't a good choice due to the engine overall construction .... so, it remaind aspirated.
What cams do you use ???
With that T3 those fuel injectors are adequate ? (no need for bigger ones or a new fuel pump?)

for the megasquirt ...

mariS_ZTi · 17-01-11, 22:19

I don't like how the standard exhaust manifold looks so I build somethig what I think that will have better airflow. It has same long lines and it has flanges at the same places like standard ones. So I will use standard exhaust from turbo. I know that I didn't find America.. It's only exhaust manifold and it cost me about 15€ and 3 afternoons of measuring, cutting and welding.

Duratec engines are pretty good for turbocharging so You can try it. If You have possibility to get the engine for good price let's do it. I'm thinking that the second engine I will build if this first will be working fine will be 2,0 zetec. It's easier to get low comp pistons, rods atc. Decompression plate isn't good way to lowering the CR if You need more boost pressure. Better way is using right pistons, cometic head gasket, ARP bolts.. But I want to make the engine about 200-220Hp in 0,8 bars of boost only for the lowest price.

Cams will be standard for the momment but my mate has NA 2,0 zetec engine with 200Hp and He is going to build something more powerfull. I would like to buy this engine and turbocharge it better way. The biggest contribution of power increase is created by the bike throttle bodies and trumpets. His engine is working with MegaSquirt like mine so the better maping has power increase too. And last thing of power increase was my vernier pulleys. He is using my owns on his race engine

My beige CVH injectors are usedable to about 220Hp what I want. If I ill need more power I will change them for something bigger and I will remaping the ecu. But 220Hp is the top of engine power with standard internals. These beige injectors are using with remapped CVH RS Turbo engine with power I said.

New fuel pump will be of course. Bosch racing pump with bigger capacity and fuel pressure regulator. And MSQ ecu will be mapped for right values of fuel pressure, air pressure from map sensor and A/F ratio from O2 sensor. This is basic for turboengine.

MegaSquirt is hell in alloy box. I absolutely don't understand of electricity. My mate is MAN in electricity so he will do it for me. My mate with racing engine will prepare the ecu with basic program and the second mate will put it to the car with all of loom, cables, sensors, gauges, lights etc. It's not so easy I think it would be but it's not impossible to finished it.