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Ford Escort Duratec 2.0 300bhp hopefully


Sultzi
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Exhaust all finished up :)

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Fabricated fuel surge tank and radiator expansion tank from 3mm alloy, friend welded them nicely..

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Made mount for the dry sump tank in the drunk

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Mounted the oil cooler pump under the floor

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Made tank straps

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Mounted the 30row oil cooler front of the radiator and started making oil lines etc
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Oil feed from pump to filter and from filter to engine
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Trunk almost done, just need to make oil catch tank and relocate tank filler to another place..
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Made bracket for that BMW electric water pump
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Thank you, let's hope it will be fun to drive :Rock:

Reinforced that gearbox mount with longitudal plates, sorry for that shit welding :welding:
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Expansion tank mounted and radiator slighty modified
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Ford dealer got me new timing cover finally
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Got pretty small Toyota's 80amp alternator from local car electrics shop..
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During this weekend I got the alternator mounted, was a bit difficult to do from alloy because I don't own a tig. So made pieces at home, then went to friend and he did tack pieces together and then back to home to make sure everything fits and then back to friend for full seams.. :rofl:

So here are the result, not pretty but will do what they should do..
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Checking the aligment..
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Alternator bolted to place. Manifold needs some heatwrap around couple first cylinders and maybe somekind of heatshield between manifold and alternator..
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  • 2 weeks later...

Small update guys..

Got new starter from sbdmotorsport for smaller 268mm flywheel (2.1kg which takes 5.5" clutch)
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Started making water pipes from 38mm alloy pipe. Lower pipe still needs An10 fitting for hose coming from expansion tank and upper pipe a bracket to hold it in place securely. Will be using that original engine mount point, this way I don't need to machine it off.
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Fabricated upper mount for the radiator, which also makes all the air go through the rad. Made also side plates for same purpose.
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Got Revotec's 15.2" fan which should flow 1800cfm. Will fabricate box behind the rad to mount the fan and also get more flow through the rad when fan is on.
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  • 2 weeks later...

Hi again, something small done, slowly getting there..

Made somekind of radiator fan mounting box. Not pretty, but needs a bit sanding and black paint, like all other parts too :)
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Then made from 2mm alloy breather tank to inner wing in the trunk. Capacity should be around 2-3litres. I know, it looks a bit strange shaped, but so does everything else in this car :D Still need to make some kind of sight to see how full the tank is and also drain line outside the car from bottom of the tank.
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Upper coolant pipe now has bracket and lower pipe has line coming from expansion tank. Still need to make that line from pump to block.
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Thank you all :)

 

Not decided with that heat shield yet, maybe I will fabricate somekind of housing back of the alternator and piping for fresh air. Also will be wrapping couple first cylinder pipes with heatwrap. Will see what I will come up with :D

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Still haven't bought new camera, so shit pictures coming..

Steering rack tacked in place where it should be, drysump scavenge lines need modification to clear steering axle coming straight back.

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And here is the front cross member all finished up, scrappy work I know, but I just need to live with it.. :lol:
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Some testing with control arm and strut in place
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Here is almost the desired ride height, steering arm needs a bit cranking downwards..
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Tarmac bilsteins are almost bottoming out in this height already and car will be a bit lower from this still..
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Thank you all :)

 

Not decided with that heat shield yet, maybe I will fabricate somekind of housing back of the alternator and piping for fresh air. Also will be wrapping couple first cylinder pipes with heatwrap. Will see what I will come up with :D

I had the exhaust manifolds on both my classic Fords ceramic coated, the mk1 by Camcoat and the mk2 Zircotec. Both seem very effective At reducing under bonnet temperature. Probably somewhere local to you can do something similar.

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I had the exhaust manifolds on both my classic Fords ceramic coated, the mk1 by Camcoat and the mk2 Zircotec. Both seem very effective At reducing under bonnet temperature. Probably somewhere local to you can do something similar.

 

Yeah, ceramic coating is also avaible here. Would be nice to coat the manifold inside and out with it..

 

Got sensor for e85 (gm continental), this works straight with DTA.

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  • 2 weeks later...

Hi guys, something small happened again.. :)

Got Audi vacuum pump for 2x remote servo's (needed to get MOT pass here in Finland)
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I mounted the servo's where the back seat used to be
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Because I have electric vacuum pump, I can switch servo's off example when going to race track to get better feel of the brakes :P

Also finally bought pipe bender, so I can start making fluid lines under the car now..
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SBDMotorsport sended new crank pulley and also crank sensor
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...and blanking plate for thermostat housing
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Started to make oil cooler fluid lines under the car, they are almost done. Couple silly curves in them, but what can you except from guy like me :D
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  • 1 year later...
  • 1 month later...

Rolled the arches little bit, still need to buy 225/45x15 r888 to the rear to see how much more is needed.
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Also have been working with the head too. Bought 1mm bigger supertech valves and started to port the head too from inlet manifold and exhaust faces. Local head guru will be doing valve seats and openings, just need to buy camshafts etc for him to do valve lash adjustment at the same time too.. After that it's pretty much done. Friend of mine did weld that egr takeoff shut.
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  • 5 years later...

Ok guys, this thing is still with me and I have now started to continue to work with this (mostly because I got the v8 cortina working last summer). And bare with me, this could be a long post (propably will do  couple different posts)

There has been changes to the powerhouse, I sold the duratec to my friend which he did put on mk2 escort and turbocharged it. Then I was left thinking what to do with the car and powertrain. Finally decided to buy Volvo five cylinder RN series 2.4l engine with mechanical tappets. I just like that five cylinder sound expesially because i'm going to fit it with some itb's.

So, first thing was to get the car from my parents house to my garage and make room for it (Cortina is sitting here also during the winter).
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Got the engine from the wreckers (these are readily avaible everywhere, used in so many cars). This one is -02 from S60 and with mechanical tappets from the factory (like duratec, no shims) also because this is a RN series engine it has lighter crankshaft and better flowing head.
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And then the ITB's, bought a set of bmw m5 v10 bodies from ebay and sold second bank bodies for the same money so these are basically free now, that's nice.
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BMW has little wider spacing but there is just enough space to make these closer each other to work with volvo engine (just needs to re drill the throttle shaft for the linkages). I then sourced different intake manifold where i cut the flange off and draw new plate for the bodies to be welded on that. I did a 3d print prototype to see if dimensions were correct and so on, all seemed fine. So i got the flange cnc machined through friend. And then another friend of mine did the welding and this did came out pretty nice. I can even use the original fuel rail with some modifications (new brackets and an fittings). In the pictures you can see couple adapters in the bodies, more about those later on.
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And then, what would I use for the gearbox :thinking: I have previosly used already mercedes 722.6 electric controlled automatic, bmw 6speed manual, quaife sequential so I wanted something new to try. So I went with BMW 7speed dct from 2016 M4. Good thing about this is that there is adapter already avaible for this engine from Domiworks Engineering in Sweden. So bought that.
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To fit this box the the engine and adapter it needed couple modifications for the bellhousing and I needed to get a T6 starter (smaller ring gear).
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After this i could test fit the box to the engine, fits nice.
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And finally I was able to lift the package in the car to see what I was dealing with. Basically need to make custom oilpan (already knew this) and some room in the gearbox tunnel at the front to get the box high as possible.
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So then I made some engine and gearbox mounts, right side is so big because there is provision for drysump pump in the future.
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Hole in the tunnel for the box. Got that filled up and also old gearstick hole also (will not be needing that anymore)
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This will do this time, will continue next time more with this :)

Edited by Sultzi
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Full on, next level engine swappage! With pic's of the engine in the bay, I thought its a tiny unit with so much space around it . . . . . then noticed the firewall and scuttle were missing LOL!

I too love the 5 cylinder growl so it'll be interesting coming out from under an Escort bonnet!

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Thanks for the positive comments 😎

Yeah, itb's in a 5 cylinder sounds pretty good, like old btcc 850 ones -> https://youtu.be/ojJ1jHFHfuE?t=107 ofcourse those rev a bit higher than this will be with this first engine (basically stock pistons, rods etc, only head will get some catcams and porting and obviosly the itbs and exhaust manifold). But i wanted to get a bit different sound from the old Escort is one reason for this engine.

And firewall is something like 30cm back.

So, let's continue with this. I draw some adapters to get somekind of baseplate mounted for the airfilter and trumpets. Luckily these bmw bodies have a nice lip where the stock airbox mounts on the m5. There is nice groove for o-ring to help keeping the adapters in place and also seal it at the same time. I then got baseplate for the air filter from ITG (jc55) with correct holes according to my drawing and luckily everything lines up nice.

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I then got some nice billet trumpets and got the test fit all together (these originally are made for weber 50 and I draw the adapters for these)

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Got some exhaust manifold flanges from stainless steel made also

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Then I measured the oilpan bolt pattern and designed a flange where I would build rest of the oilpan. First made 3d print for checking dimensions and all checked out good so then got the flange water cutted from 20mm aluminium. Oil filter needs to be relocated (will weld couple an10 fittings on the flange), original one is front of the oil pan just where steering rack is in this car.

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I was first thinking making the oilpump suction with external line, but wound out I can make the original pickup work with little modifications (extended one cylinder backwards). And the flange needed cutaway for it and also I needed to grind room for couple crankshaft main bolt heads. 

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Still got nice room with radiator and fan

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This is also going to be DBW like the Cortina, so I bought BMW E46 M3 throttle actuator. I like this version better because this has basically standard tps sensor for the motor position which I can replace (without replacing whole actuator).

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Bought couple Cobra seat replicas so i could start to fit the Corsa power steering column.

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Currently working on the steering shaft from the column to the rack and many other things at the same time, more about these later on.

Edited by Sultzi
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