1994 - Ford Escort Cosworth - power steering fluid tank

After a bit of recovery time from my anual pillgramage to Bloodstock festival I did some work on the escort.

I need to do a cable transit for the bulkhead, but don't want to have to strip the connector to pass through the cables, so another two piece transit. A bit simpler than the other one as it doesnt have anythign like the amount of cables to lean on it.

I tried out some things in cardboard, then start to convert to aluminium

P1060607 by jono_misfit, on Flickr

cut out, trimmed and added a step

P1060608 by jono_misfit, on Flickr

go together like so

P1060609 by jono_misfit, on Flickr

i've put a lip on the back to stiffen it up and ensure it it can push evenly on the gasket

P1060610 by jono_misfit, on Flickr

goes in like so

P1060611 by jono_misfit, on Flickr

gasket still to fit

P1060612 by jono_misfit, on Flickr

This splits in two and the top half lifts out to allow cables & connectors to go through. I don't think I need to wire any more through it, but its there if I need to.

I then connected up my spare battery and started the task of checking the electrics work.

Very helpfully I have lost ALL the notes I made when doing the wiring, all my relay, fuse, connection details. gone. I saw them the other week, but having turned the workshop and house upside down I still cant find them.

Had to start belling things out and trial and error to work things out again.

New notes, and check off lists for the checks I made.

P1060613 by jono_misfit, on Flickr

Main faults so far.. the rear side light and fog lights connections are swapped on the nearside.

I couldnt get the blower fan to run in the car. A quick strip down and direct connect to the batter shows a very lazy motor. replacement motorfans are available.

P1060614 by jono_misfit, on Flickr

the resistor block connections have seen better days. I'll need to do some digging as a quick search doesnt show any.

P1060615 by jono_misfit, on Flickr

P1060617 by jono_misfit, on Flickr

I got fed up playing guess the switch so got the labeling machine out.

P1060618 by jono_misfit, on Flickr

I could do with taking the dash panel out again, taping a line, and redoing them so they are all straight.

then put the dash back in

P1060620 by jono_misfit, on Flickr

and played around until it turned on

P1060621 by jono_misfit, on Flickr

some of the lights already work, which is good. (indicators for the right trun direction, and fog)

P1060623 by jono_misfit, on Flickr

But for some reason the backlight isnt coming on. I'll need to look into this as its likely a connection issue somewhere.

made the tube clip

P1060643 by jono_misfit, on Flickr

to go here

P1060642 by jono_misfit, on Flickr

I made the bridge piece and welded it on

P1060644 by jono_misfit, on Flickr

fits like so

P1060645 by jono_misfit, on Flickr

aluminium hose vapour barrier goes over and it end up like so

P1060646 by jono_misfit, on Flickr

P1060647 by jono_misfit, on Flickr

onto the next job

spare wheel holder

P1060649 by jono_misfit, on Flickr

for in here

P1060648 by jono_misfit, on Flickr

need something like so

P1060650 by jono_misfit, on Flickr

rough cut the ali

P1060651 by jono_misfit, on Flickr

P1060653 by jono_misfit, on Flickr

sits in like so

P1060654 by jono_misfit, on Flickr

Should be doing more on the escort tomorrow

Nice hi quality progress. Didn’t understand the filler hose mount until the Vapor hose got added. Is this a regulations requirement ?
James

It was a bit of an odds and sods day on the escort.

I started on the fuel rpessure regulator, then realised I'd forgotten to order a fitting I needed so could only make 1 pipe. Doh.

P1060677 by jono_misfit, on Flickr

the spare wheel strap turned up so fitted that.

Checking for position

P1060678 by jono_misfit, on Flickr

then bolted in

P1060679 by jono_misfit, on Flickr

holds it pretty secure when the ratchet is done up. I may still make a lower wheel fence to hold it centrally.

P1060680 by jono_misfit, on Flickr

M10 bolts to hold it down

P1060681 by jono_misfit, on Flickr

P1060682 by jono_misfit, on Flickr

P1060683 by jono_misfit, on Flickr

Then went on to remake the brake balance bar extension pieces as my hex bar & taps had turned up.

Piece 1 turned and threaded

P1060684 by jono_misfit, on Flickr

checking thread fit

P1060685 by jono_misfit, on Flickr

fits on like so

P1060686 by jono_misfit, on Flickr

and second one made

P1060687 by jono_misfit, on Flickr

P1060688 by jono_misfit, on Flickr

I could have gone down a couple of sized on hex bar, but it'll do as it is. I'll remake them if I decide grams of weight on the car are important

in situ

P1060689 by jono_misfit, on Flickr

P1060690 by jono_misfit, on Flickr

From the above I clocked I hadnt alligned the rods properly, so dismantled and did again so the bars are much closer to parallell.

I also looked at the pedal positions, and I think i need to take about 10mm from the threaded ends of the adjusters to bring it back to alignment.

mounted the brake bias adjuster

P1060691 by jono_misfit, on Flickr

P1060692 by jono_misfit, on Flickr

Mounted some pedal plates (which from the photo angle look squint, but on the car the were aligned)

P1060693 by jono_misfit, on Flickr

I moved the throttle pedal plate closer to the brake pedal to make heel and toe easier.

painted and fitted grip tape to the clutch foot rest. I bought a sheet of skateboard deck grip and cut out the size I needed. Cheep and readily replaceale when it wears out.

P1060694 by jono_misfit, on Flickr

P1060695 by jono_misfit, on Flickr

(from this pic the throttle pedal plate looks squint, so will need to go and look at that again)

then started looking at the radiator and fans

P1060696 by jono_misfit, on Flickr

took some dims

P1060697 by jono_misfit, on Flickr

started converting to aluminium

P1060698 by jono_misfit, on Flickr

fan goes like so

P1060699 by jono_misfit, on Flickr

two fans fit like so

P1060700 by jono_misfit, on Flickr

The fan kit just came with some through radiator ties to hold the fans on, but I really don't like them as they look perfect for fretting the radiator. This will be a mounting plate with a lot of cut outs and be slightly spaced off the radiator face. I'll be cutting out most of the surface to make sure the is good airflow passage.

what thickness is the aluminium ?

having seen ac system condenser fans break brackets made of steel of similar thickness I suspect you'll be revisiting those mountsat some point

I fitted some spiral wrap protection to the braided hoses

P1060734 by jono_misfit, on Flickr

P1060738 by jono_misfit, on Flickr

and fited the tank straps.

P1060733 by jono_misfit, on Flickr

I still need to cut and fit the 3mm rubber under the tank hence the 3mm rubber strips under the straps. There's also a 1mm rubber strip on the underside of the straps and I've fitted 1mm rubber to the lateral mvoement tabs.

fitted the pull T-handles. Red for fire, black for isolator

P1060736 by jono_misfit, on Flickr

and routed to where the fre extinguisher will be

P1060737 by jono_misfit, on Flickr

then started marking up for the fuel guage

P1060740 by jono_misfit, on Flickr

ali
P1060741 by jono_misfit, on Flickr

P1060742 by jono_misfit, on Flickr

ready to cut for the gauge when I get it

P1060743 by jono_misfit, on Flickr

marked up the centre console showing what fuse is what

P1060745 by jono_misfit, on Flickr

P1060746 by jono_misfit, on Flickr

I stripped the blower fan again, cleaned up contacts on the motor, replaced the speed resistor (with a modified transit one as I cant find the proper one)

P1060747 by jono_misfit, on Flickr

found some holes i'd missed and put on the silver tape

P1060748 by jono_misfit, on Flickr

mounted the ECU into what was the glove box, and fitted the blanking plate to the dashboard (abeit temporarily as I havent connected it up)

P1060749 by jono_misfit, on Flickr

and painted the foot rest. I'll give it a week to cure then fit the grip tape

P1060750 by jono_misfit, on Flickr

Thanks.

I have the large washers for the balance bar to go in still. Its mainly waiting for me to take it all apart again, take 10mm off the end of adaptors I made for the push rods, and final assemble.

Usefull info to know for when I do the final assembly.

Temp fitted the front indicators

P1060751 by jono_misfit, on Flickr

to check for clearance

P1060752 by jono_misfit, on Flickr

not a huge amount of space, but it all fits

fitted skateboard grip tape to the passenger foot brace

P1060753 by jono_misfit, on Flickr

and temp fitted back in the car

P1060754 by jono_misfit, on Flickr

From memory its fairly close between the brake / clutch cylinders and the rigth bank exhaust manifold. I don't fancy them cooking so it needs a heat shield. Its a catch 22. I'd like the engine in so I can certain of space, but it'll be a pain in the backside to do with the engine in I think.

Do it whilst theres space I think. Will go here.

P1060755 by jono_misfit, on Flickr

start with the normal place

P1060756 by jono_misfit, on Flickr

goes in here

P1060757 by jono_misfit, on Flickr

P1060758 by jono_misfit, on Flickr

forget to take pictures for a while, but normal convert to aluminium, cut, fold, hammer.

gives this, although I decided to round the corners .... because....

P1060759 by jono_misfit, on Flickr

an application of the sparky hot glue gun gives

P1060760 by jono_misfit, on Flickr

drill some holes for access and drains

P1060761 by jono_misfit, on Flickr

fits like so

P1060762 by jono_misfit, on Flickr

P1060763 by jono_misfit, on Flickr

add a second bolt access hole

P1060764 by jono_misfit, on Flickr

It'll get covered with heat reflective material.... once I know there isnt an engine interference...