How did you go even finding all the emissions gear you needed?  Courtesy of the kind folks here on classic-ford. org?

From my experiences as long as there are a crap load of hoses going vaugely in the right direction  they usually pass it.
 
Matt

Flighter

How did you go even finding all the emissions gear you needed?  Courtesy of the kind folks here on classic-ford. org?

 
Hi Flighter, I got all the help I could need from the experts here and on Classic Speed Restored. It's fantastic to have such a great resource to rely on.
I don't think there's a problem exist that can't be resolved!!

In the end I think I managed to source all emission components, and got everything running basically as Ford originally intended.
The whole setup has been running for the last couple of years without a problem.
The only drama I had was a couple of weeks ago when the original oil pressure gauge line ruptured and caused a fire in the engine bay!!!
Luckily I smothered it before we lost another Escort in a fireball.

Speaker hole repaired.

is that fibreglass? I need to fix speaker holes in my 4 door RS as well.
Funny you mention the oil line rupturing, on my RS which I restored in 97 ( and am doing so again - very long story!) It was all freshly painted with new motor installed 2 weeks out from the summernats I was entered in. We started up the engine to bed in the cam and oil started leaking out the rocker cover. The mob who built the engine left the rocker cover bolts loose and being inexperienced it never occured to me to check. I didnt want to stop the motor because I was scared this may affect the cam bedding in process. So after about 2 minuted the oil drips onto the extractors, catches alight, that fire then melted the plastic oil pressure line which started spurting oil and subsequently a massive fire in my brand new car! Luckily I had a powder extinguisher mounted in the car and got the fire out pretty quickly but the dry powder somehow damaged the paint under the bonnet ,on the rocker cover and a few other ancillaries. So, I tighten up all the rocker cover bolts and snap the last bolts head off ( I think it was damaged as it took bugger all torque compared to the others) Being in a rush to get the car ready for summernats my brother says he can get the snapped bolt out with an ezy out ( engine is still hot at this stage), and then snaps the ezy out off in the snapped off bolt in my $2000 head ( in 97 prices!). Result was 2 days of toil to get the ezy out , out and the hole repaired.
   Hopefully your fire wasnt as bad as mine!!!!!!!!!!!

Gee Mick, that sounds like incredible drama,lucky you didn't lose the lot!
I was idling for a few minutes when suddenly smoke or steam started spewing out of the bonnet, I pulled the bonnet release and jumped out to discover it was smoke.
I took off my shirt and braced myself for the worst and lifted the hood. There was a small fire in the back left corner which I smothered with my shirt.
I don't know how after 32 years the oil line just decided to rupture but that was the cause, the fire had just begun to melt the water bottle motor, clutch cable and a couple of water hoses.
The safest fix is to install one of these.

I've since finally bought a CAMS extinguisher, which will be installed before I ever drive the car again!! 
With the speaker holes I just cut out a section from the discarded door card.

I bought a new oil pressure line from england. Its still the plastic one but all new pipe and fittings. I guess it could be ok to lap wrap the line in some black heat wrap like exhaust wrap.
  I never thought of using some old card to fill the holes. How did you glue it. Some high strength silastic may be flexible but still have a good bond strength.

Patching up the plastic, even managed to use some plastic packaging from a PC mouse for the ash tray cover.

Final result.

Interior with new front carpet.

Looks great mate.
 
Matt