My 500bhp Escort RS Turbo build
Discussion
Hello all,
Bit of an introduction post, I'm Will, 22 and from Blackpool - work as Workshop Manager for Motorsport Developments and have previously worked for RC Developments and Honda Racing F1.
Thought i'd share with you a few pics of my little project (only 3 years in the making so far!)
Well, it all started when I bought an MOT Failure Escort RS Turbo with thoughts of either getting it back on the road as it was or reshelling it:
Sure enough, the rot was found to be too far gone – so I stripped it:
And scrapped the shell!
I was then offered a “Solid” shell for a few hundred quid which being young and naïve – I bought… I fitted the best of both cars to it:
I then got hold of a 90 Spec Front Bumper and Rear Spoiler (still attached to a tailgate lol) and fitted them:
Around this time I was put in touch with a guy called Chris, a true petrolhead, owner of a 1000bhp Chevy drag car, Escort Cosworth and a few other select cars! Capable of building hot rods from scratch he seemed a good choice to carry out the restoration and respray on mine – so he came to get it!
Whilst the car was off on its holidays I thought that it would be a shame to put a 1.6 CVH engine back in when I was offered an engine I had always admired…
A Power Engineering built 2.0 Zetec which had been in the Ford Focus Owners Club chairmans car for 5000 miles. I bought this and the Focus RS Gearbox off him!
I also managed to get an intercooler that literally sits between the headlights! PS2 controller on there to indicate size!
And a bit of playing around with Photoshop confirmed to me that Mitsubishi Evo 8 MR Gunmetal Grey with Matt Black Wheels and Carbon Detailing was the look wanted!
By this time Chris had made good inroads into the “Solid Shell” – famous last words!
Eventually getting down to metal again!
New panels went on:
Various other bits were tidied up:
Unfortunately these photos are the last set I received from Chris, he sustained an injury to his arm last year and contracted a superbug whilst receiving treatment in hospital and I am still waiting for him to return to work.
Around this time I started spending all my apprentice wages and savings on other bits for the car:
Compbrake 315mm 4 Pots:
Defi Gauges:
Defi Boost Gauge & Aquamist Gauge
WRC CGI Block:
WRC Water Pump:
WRC Plenum Chamber:
I managed to get my SPA Speedometer and ATL Fuel Level Gauge and mocked them all out ready to set into carbon:
I had some machining work done on the plenum to accept an Aeromotive Fuel Filter and some end caps made to hold it in place:
Also designed some adaptor plates to mount my Titan Roller Barrel Throttle Bodies to the plenum:
With my Siemens 650cc Injectors and DCOE Inlet Manifold I had all the inlet side of things covered:
While I was shopping with Webster Race Engineering I also got my Aeromotive A1000 Fuel Pump:
Aeromotive Pre Pump Filter:
Aeromotive Fuel Pressure Regulator:
MSD Coilpack:
Also managed to get all new gaskets, seals, nuts and bolts from Ford for the engine build:
Brand new ST170 Rocker Cover, TIS & Microcat:
Billet Geared Oil Pump & WRC Water Pump:
Loads of Aeroquip:
Nitrous bits:
WRC Inconel Exhaust Manifold:
Individual Primary Lambda Sensors and EGT Probes:
My friend Lee machined me a bracket for my Fuel Pressure Reg & Nitrous Solenoid:
With lightening!
Which when mocked up:
Finished setting the dash into carbon:
And decided to replace the aquamist gauge in the A-pillar for my AEM wideband lambda:
The head has been flowed over 400 times and worked on for 10 days... it's on +1mm oversize ferrea valves and can now flow:
323bhp @ 13mm Valve Lift @ 10" Water
Equates to 198 Cubic Feet of air per Minute
That's half a milk bottle of material removed from the head
I also had the DCOE inlet manifold and gasket port matched to suit.
Right - pics!
DCOE inlet manifold fitted up:
The ports going to the head:
Looking inside the DCOE manifold up into the throttle bodies - you can clearly see the injector nozzle!
Now for the head
Inlet ports:
Close up of the port:
Exhaust ports:
Close up of the port:
Now for the fun stuff... Just got back from the states and did a little bit of christmas shopping while i was there
Turbonetics GTK-450 (The GTK stands for GT Killer)
Truly an amazing bit of kit - phenomenal development work in this little beauty
Runs a ported shroud to reduce surge, a thermal coating on the housing face to keep heat soak down, a HIP (Hot Isostatic Process) compressor wheel amongst other trickery...
Comes straight from the factory with an inline oil feed filter and the label shows the unit tested oil flow rate:
From the factory the exhaust housing has a funky heat proof coating:
Oh and it's an inconel exhaust wheel and shaft:
And just to give you an idea of size:
Also got my hands on one of the special edition black face AVCR boost controllers, when set up fully, these things are phenomenal!
Few more AEM goodies while i wait for my ECU and loom to arrive (should be within a week or so) - Here we have a 4 channel thermocouple amplifier, 3.5 Bar MAP sensor, air temp sensor, oil pressure sensor and water temp sensor.
Turbosmart 38mm External Hi Temp Wastegate:
See if you can guess what this is:
Oh ok - it's a Turbosmart Race Port BOV (Blow Off Valve)
Here we see the Lucky Strike ruler showing that this is not a piddly 20mm diameter piston in it... There'll be no PPPPTISSCHHH noise with this... just the sound of all the compressed air vanishing to atmosphere instantly :king:
It's all starting to come together now...
Full engine spec list:
WRC CGI Block
CP Forged Pistons
Crower Forged Conrods
ARP 2000 Rod Bolts
Nitrided & Balanced Crank
ACL Race Spec Bearings
Billet Geared Oil Pump
ARP Stud & Nut Kit
Ported ST170 Cylinder Head
+1mm Oversize Ferrea Valves
Custom Spec Double Valve Spring Kit
Ferrea Single Groove Race Collets
Titanium Retainers
Piper Inlet Cam
Piper Vernier Pulleys
WRC Water Pump
Titan Roller Barrel Thottle Bodies
Port Matched DCOE Manifold
Custom Adaption Plates
WRC Rear Plenum Section
Siemens 65lb Injectors
Holley Wet Nitrous Kit
WRC Inconel Exhaust Manifold with Individual Lambda/EGT
Turbonetics GT-K450 Turbo
Turbosmart 38mm External Wastegate
Turbosmart Race Port
AEM Standalone Engine Management
Aeromotive Fuel Pressure Regulator
Comments welcome
Bit of an introduction post, I'm Will, 22 and from Blackpool - work as Workshop Manager for Motorsport Developments and have previously worked for RC Developments and Honda Racing F1.
Thought i'd share with you a few pics of my little project (only 3 years in the making so far!)
Well, it all started when I bought an MOT Failure Escort RS Turbo with thoughts of either getting it back on the road as it was or reshelling it:
Sure enough, the rot was found to be too far gone – so I stripped it:
And scrapped the shell!
I was then offered a “Solid” shell for a few hundred quid which being young and naïve – I bought… I fitted the best of both cars to it:
I then got hold of a 90 Spec Front Bumper and Rear Spoiler (still attached to a tailgate lol) and fitted them:
Around this time I was put in touch with a guy called Chris, a true petrolhead, owner of a 1000bhp Chevy drag car, Escort Cosworth and a few other select cars! Capable of building hot rods from scratch he seemed a good choice to carry out the restoration and respray on mine – so he came to get it!
Whilst the car was off on its holidays I thought that it would be a shame to put a 1.6 CVH engine back in when I was offered an engine I had always admired…
A Power Engineering built 2.0 Zetec which had been in the Ford Focus Owners Club chairmans car for 5000 miles. I bought this and the Focus RS Gearbox off him!
I also managed to get an intercooler that literally sits between the headlights! PS2 controller on there to indicate size!
And a bit of playing around with Photoshop confirmed to me that Mitsubishi Evo 8 MR Gunmetal Grey with Matt Black Wheels and Carbon Detailing was the look wanted!
By this time Chris had made good inroads into the “Solid Shell” – famous last words!
Eventually getting down to metal again!
New panels went on:
Various other bits were tidied up:
Unfortunately these photos are the last set I received from Chris, he sustained an injury to his arm last year and contracted a superbug whilst receiving treatment in hospital and I am still waiting for him to return to work.
Around this time I started spending all my apprentice wages and savings on other bits for the car:
Compbrake 315mm 4 Pots:
Defi Gauges:
Defi Boost Gauge & Aquamist Gauge
WRC CGI Block:
WRC Water Pump:
WRC Plenum Chamber:
I managed to get my SPA Speedometer and ATL Fuel Level Gauge and mocked them all out ready to set into carbon:
I had some machining work done on the plenum to accept an Aeromotive Fuel Filter and some end caps made to hold it in place:
Also designed some adaptor plates to mount my Titan Roller Barrel Throttle Bodies to the plenum:
With my Siemens 650cc Injectors and DCOE Inlet Manifold I had all the inlet side of things covered:
While I was shopping with Webster Race Engineering I also got my Aeromotive A1000 Fuel Pump:
Aeromotive Pre Pump Filter:
Aeromotive Fuel Pressure Regulator:
MSD Coilpack:
Also managed to get all new gaskets, seals, nuts and bolts from Ford for the engine build:
Brand new ST170 Rocker Cover, TIS & Microcat:
Billet Geared Oil Pump & WRC Water Pump:
Loads of Aeroquip:
Nitrous bits:
WRC Inconel Exhaust Manifold:
Individual Primary Lambda Sensors and EGT Probes:
My friend Lee machined me a bracket for my Fuel Pressure Reg & Nitrous Solenoid:
With lightening!
Which when mocked up:
Finished setting the dash into carbon:
And decided to replace the aquamist gauge in the A-pillar for my AEM wideband lambda:
The head has been flowed over 400 times and worked on for 10 days... it's on +1mm oversize ferrea valves and can now flow:
323bhp @ 13mm Valve Lift @ 10" Water
Equates to 198 Cubic Feet of air per Minute
That's half a milk bottle of material removed from the head
I also had the DCOE inlet manifold and gasket port matched to suit.
Right - pics!
DCOE inlet manifold fitted up:
The ports going to the head:
Looking inside the DCOE manifold up into the throttle bodies - you can clearly see the injector nozzle!
Now for the head
Inlet ports:
Close up of the port:
Exhaust ports:
Close up of the port:
Now for the fun stuff... Just got back from the states and did a little bit of christmas shopping while i was there
Turbonetics GTK-450 (The GTK stands for GT Killer)
Truly an amazing bit of kit - phenomenal development work in this little beauty
Runs a ported shroud to reduce surge, a thermal coating on the housing face to keep heat soak down, a HIP (Hot Isostatic Process) compressor wheel amongst other trickery...
Comes straight from the factory with an inline oil feed filter and the label shows the unit tested oil flow rate:
From the factory the exhaust housing has a funky heat proof coating:
Oh and it's an inconel exhaust wheel and shaft:
And just to give you an idea of size:
Also got my hands on one of the special edition black face AVCR boost controllers, when set up fully, these things are phenomenal!
Few more AEM goodies while i wait for my ECU and loom to arrive (should be within a week or so) - Here we have a 4 channel thermocouple amplifier, 3.5 Bar MAP sensor, air temp sensor, oil pressure sensor and water temp sensor.
Turbosmart 38mm External Hi Temp Wastegate:
See if you can guess what this is:
Oh ok - it's a Turbosmart Race Port BOV (Blow Off Valve)
Here we see the Lucky Strike ruler showing that this is not a piddly 20mm diameter piston in it... There'll be no PPPPTISSCHHH noise with this... just the sound of all the compressed air vanishing to atmosphere instantly :king:
It's all starting to come together now...
Full engine spec list:
WRC CGI Block
CP Forged Pistons
Crower Forged Conrods
ARP 2000 Rod Bolts
Nitrided & Balanced Crank
ACL Race Spec Bearings
Billet Geared Oil Pump
ARP Stud & Nut Kit
Ported ST170 Cylinder Head
+1mm Oversize Ferrea Valves
Custom Spec Double Valve Spring Kit
Ferrea Single Groove Race Collets
Titanium Retainers
Piper Inlet Cam
Piper Vernier Pulleys
WRC Water Pump
Titan Roller Barrel Thottle Bodies
Port Matched DCOE Manifold
Custom Adaption Plates
WRC Rear Plenum Section
Siemens 65lb Injectors
Holley Wet Nitrous Kit
WRC Inconel Exhaust Manifold with Individual Lambda/EGT
Turbonetics GT-K450 Turbo
Turbosmart 38mm External Wastegate
Turbosmart Race Port
AEM Standalone Engine Management
Aeromotive Fuel Pressure Regulator
Comments welcome
AndyBe - No ICE lol...
The engine and box weren't too hard to mount once Chris has modified the inner wings and torque damepened the box from the 'strut brace' section of the cage...
Front tyres - Yokohama AO48Rs.... won't be cheap!
Thanks for the interest guys - i'll update as it happens...
The engine and box weren't too hard to mount once Chris has modified the inner wings and torque damepened the box from the 'strut brace' section of the cage...
Front tyres - Yokohama AO48Rs.... won't be cheap!
Thanks for the interest guys - i'll update as it happens...
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