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Hot!Paul's Mk2 RS2000 project - Now going ZETEC!

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Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2020/04/04 13:01:43 (permalink)
+1 (1)
I’m sure it was from a late model Fiesta etc. I had a few options as some of the older inserts were metal but this one was plastic which clipped into the steel outer tube. I cut off the very end of the original Escort filler and with a bit of fettling it was a snug fit and sealed with JB Weld. I had to use the smaller cap from the earlier steel insert as it gave more clearance to the number plate. If I use the larger (and possibly a locking) fuel cap the “handle” has to be horizontal to clear the number plate.

Cheers

Paul
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2020/04/17 21:02:58 (permalink)
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Hi paul

Another question, i was browsing your thread and seen you used KBS rust shield on your diff. Im building up a pigs head with LSD and was going to paint it but after seeing you liked the product have ordered some. If i tape off the areas (mating surfaces) will that be enough? i just want to make sure i dont get any leaks due to the paints getting into areas i dont want it.
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2020/04/17 21:49:07 (permalink)
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Hi Robbie. Yes the KBS stuff is great. Goes on smooth, covers well and is rock hard when cured. Just use gloves as it’s impossible to get off your hands.

Cheers

Paul

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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2020/04/17 22:04:14 (permalink)
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Thanks, finding gloves in this day and age!

So if i tape up it should be fine?
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2020/04/17 23:22:59 (permalink)
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Absolutely although as it’s brushed on it’s not hard to paint around key mating surfaces without the need for masking.

Cheers

Paul
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2020/04/21 19:43:24 (permalink)
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Sorry for the constant harassment paul 

Whats the plan for egr?
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2020/04/21 23:30:50 (permalink)
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I'm not is the short answer.

Cheers

Paul
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2020/04/22 09:26:32 (permalink)
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Ha ok, then!
Robbie
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2021/06/08 16:14:40 (permalink)
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Been thinking of this build i a bit more lately, hows things progressing Paul?
 
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2021/06/12 09:58:12 (permalink)
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Hi Robbie. Not a great deal to report.
Engine build is currently waiting on piston machining as too much compression. My pistons / rods are for a blacktop and reportedly 11:1 but in a Silvertop they’re well over 12:1 due to smaller combustion chambers (45 vs 48cc). Will end up at a more 98 pump fuel friendly ratio of 10.5:1.
After discussions with my engineer I had to remove and modify my EPAS unit but that's all back in now.
Inlet manifold nearly done as I couldn't find a 40mm DCOE manifold to suit as I have the EFI hardware "race" tapered units (45 - 40mm) - just deciding if I get it ceramic coated or powder coated.
Just battling with the hood lining.
post edited by Paul Dunstan - 2021/06/12 10:20:47

Attached Image(s)


Cheers

Paul
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2021/06/12 15:32:44 (permalink)
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Thanks for the update paul, the headliner looks very neat and puts mine to shame.

What was the issue with the EPAS? Glad to hear it was a easy fix.

I vote manifold to be black, would be cool to do the TB black also but thats just me.
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2021/06/12 17:26:30 (permalink)
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Yeah. I would like black too but not easy to to the TB’s unfortunately so I’m thinking silver ceramic coating as doing the headers and water rail too. Much easier to keep them clean.
The headlining isn’t finished yet as still scared to cut anything 😂.
Issue with EPAS was the way I adapted to the original Escort column. All joins are required to be mechanical (splines etc) and any welding or steering components is not permitted. Hence I had to spline the output and use a D joint at the top on the input. Helps to have a mate who’s a machinist 😁.
I have also splined the spare one also so it’s compliment 😉
Also, the trumpets are what came with the TB’s and although hidden behind the filter I think I will replace them🤔

Cheers

Paul
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2021/06/12 17:41:51 (permalink)
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Sorry to hear about the hurdles Paul, but glad to see you're jumping them and the progress pics look great.
 
Bit of info on ceramic coating manifolds here
Intake Manifold Coatings – CIC High Performance Ceramics (cicceramics.com.au)

GT Cortina Project "The Ugly Duckling"
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2021/06/12 17:58:28 (permalink)
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Wasn’t really a hurdle more of a learning experience and to always consult your engineer BEFORE modifying anything like that 🙄. Thanks for the info and there’s a mob in Adelaide who I will likely use - think they’re called Ceramic Coat Australia.

Cheers

Paul
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2021/06/12 17:59:42 (permalink)
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Hi Paul ,
Looks like you got the positions of the ribs for the headlining sorted, liner is nice and taut. When it comes time to glue everything in place around door/ window openings, make sure you mark the positions of the screw holes for grab handles, sun visors, C pillar trims etc so you don't have to fish around for them like I had to!
Cheers,
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