kingcosworth
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Cosworth Mk2 Escort build
How's it all going, thought some people might be interested in my escort that should be up and running very shortly!!! It's running a YB Cosworth, mountune cams, Mahle pistons, Haltech E8, Custom plenum, extensive head work, custom exhaust manifold, 42mm external wastegate, T3/4 turbo (to begin with). Interior will be full leather, Focal stereo, Jarrah high lights, so on, so on! It's on the home stretch now, some of these photos are a bit aged, it's a bit further on than what the pictures indicate, hope you guys like it!!!            
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Steviestar
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RE: Cosworth Mk2 Escort build
2009/10/31 00:46:20
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Daaaamn, will have to keep an eye on this beast
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Phil
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RE: Cosworth Mk2 Escort build
2009/10/31 07:46:38
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Hi Chris, It looks great,and should go well too 
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escortinadriver
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RE: Cosworth Mk2 Escort build
2009/10/31 10:01:07
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Nice first post.... Welcome to the forum. Show us more.. Shaun
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kingcosworth
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RE: Cosworth Mk2 Escort build
2009/10/31 10:31:15
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Thanks for all the good words!!! The front struts consist of capri struts, XF ventilated rear discs over hubs made from P76 rotors, the calipers are volvo steel 4 spots on some adapter brackets I milled out of 25mm stock. sorry about all the ugliness of the parts, they were in there when the body got sprayed, it's all been cleaned up and made pretty again now!!! Just haven't got any new new photos.  
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Mk2_2dr_2L
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RE: Cosworth Mk2 Escort build
2009/10/31 10:42:45
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Not bad  What gearbox are you running ? And what are you doing Intercooler, radiator and fan wise ? Cheers, Damion
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kingcosworth
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RE: Cosworth Mk2 Escort build
2009/10/31 11:03:12
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I sourced a core, and built the tanks for the intercooler. I had to cut out part of the front sheet metal and make some sheet metal boxes to seal everything up nicely, the intercooler is 50mm thick, and it all fits behind the grill. I will be using an alloy aussie desert cooler radiator, electric waterpump, as for the fan, not sure just yet, I'll work it out when I drop the motor in, because as you know, theres bugger all room down there, but the electric water pump should free up some room!! 
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kingcosworth
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RE: Cosworth Mk2 Escort build
2009/10/31 11:07:25
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Sorry forgot to mention, I've got a steel case celica box, still haven't rebuilt it, but i'll get around to it, i'll fit it with that beefed up input bearing. I have a dellow bellhousing, i've had to put it on the lathe and clearence it out a fraction to clear the cosworth flywheel, but I still have starter motor issues, I'm thinking of a plate to offset it out and bring it back, but i'm not at that stage just yet.
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Mark
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RE: Cosworth Mk2 Escort build
2009/10/31 17:18:03
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quote:
Originally posted by kingcosworth
Sorry forgot to mention, I've got a steel case celica box, still haven't rebuilt it, but i'll get around to it, i'll fit it with that beefed up input bearing. I have a dellow bellhousing, i've had to put it on the lathe and clearence it out a fraction to clear the cosworth flywheel, but I still have starter motor issues, I'm thinking of a plate to offset it out and bring it back, but i'm not at that stage just yet.
...For sure you will end up with the need to change the gears in the celica steel case box to wider and stronger gears, straight cut is an option. I blew 2-off gearboxes from torque, no burn outs etc, just coming on boost and the cluster just could not take it. My new custom ratio straight cut gears are magic and not as noisy as people think due to the modern machining capabilities, grinding shape and accuracy. One way that you can solve the flywheel issue is by changing the ring gear to a pinto item and then the dellow bell housing will fit, use a 4x4 cosworth starter motor (nice little compact one they are) and an adaptor spigot ring. Else just move the starter out further, the only drama there is how to get the gear mesh spot on.
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kingcosworth
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RE: Cosworth Mk2 Escort build
2009/10/31 19:00:34
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Thanks for the advice, it's good to hear from someone who has gone through these headaches, I just want to clarify some points. Who machined up your gearset for you, and how were the old ones failing, stripped teeth?? How did you go about put the pinto ring gear on it, admitingly it has been a while since I played with the flywheel, but it looked that the pinto gear couldn't go on the front in the stock pinto spot becuase of the bigger pressure plate, it could go on the back but there would be a flange created infront of the ring gear! Which set up are you running??? The other problem I have is I have machined off the inside of the flywheel weight, so I can't knock that diameter down anymore
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LINCOLN
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RE: Cosworth Mk2 Escort build
2009/10/31 21:59:54
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Nice.
I have a standard 2wd cos flywheel taking up space here.
Yours for nix if you need it - it has got no ring gear though. Melbourne
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Mk2_2dr_2L
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RE: Cosworth Mk2 Escort build
2009/01/11 09:29:37
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Yeah it is very tight in there, I have just gone and modified my engine mounts and trimmed the lip on my firewall to get everything 25mm further back for a bit more room for better fans, fingers crossed it will be worth the effort. I looked into an electric water pump about a year ago and it would definately make way for fan space.. I think the alternator is the only major thing in your road then. I was worried about the reliability of the EWP as a lot of people seem to have trouble with them.
There are a couple of guys up here that have run some fairly serious cosworth powered IP cars with steel cases (obviously power limited by the restrictor) and they have survived. I guess try it with a better input bearing and see how you go. I was told that there are two types of W50 box one of which came out of the twin cam and has a better input bearing. I am not sure of the spec of your turbo or what cams you are running ?
Try to avoid running a smaller clutch, I am not exactly sure what trickery Mark has done to use the cosworth clutch but from my measurements the mounting PCD for the cossie clutch would be bolting into the pinto ring gear rather than the flyweel. I use a custom flywheel with a pinto ring gear/starter etc and I wouldn't recommend it unless you go to a twin plate clutch straight up.. I have had untold trouble with clutches.
Cheers.
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kingcosworth
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RE: Cosworth Mk2 Escort build
2009/01/11 11:44:41
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Yeh thats what I found as well regarding the PCD and ring gear. I'll look into the 4x4 starter and I guess even the possibility of putting a new stater flange on the bellhousing. Yeh i'll definattly stick with the 11in plate. I'm looking at about 500hp from the motor, the mountune cams are 9mm ex 12mm in for the lift, but I haven't dialled them yet for duration numbers, I've got ARP head and main studs all through it. You guys will cringe at this but i'm using a pinto block, I've got an early one from a TC cortina HC motor, and it actually has extra bracing cast into the side of it???? I know the bores are a fraction thinner, but i'm only running 20thou over pistons and I figure when cosworth designed the block, it was expect to produce 500-600hp for 8,9,10 hours at a time, If I try this, I would lose my licence in the first hour! I am how ever looking into get the block cryoed before I bolt the lot together.
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kingcosworth
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RE: Cosworth Mk2 Escort build
2009/01/11 11:45:45
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What sort of cash did you want for that flywheel lincoln?
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maxrs
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RE: Cosworth Mk2 Escort build
2009/01/11 12:06:38
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Welcome MR King.
I have been a fan of the Cortina 2l blocks, but i would be grout filling the block if you want it stay together with 2 bars of boost up its bum.
Looking great anyway dude, looking forward to more updates on this project.
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