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West of Scotland RSOC • View topic - Escort RS Cosworth: C6 SSY Project Thread - Updated 2.6.13

Escort RS Cosworth: C6 SSY Project Thread - Updated 2.6.13

For all your resto & rebuild Pics.

Escort RS Cosworth: C6 SSY Project Thread - Updated 2.6.13

Postby AGAR » Mon May 27, 2013 7:38 pm

Hi,

I haven't really been active on here since I broke my Fiesta in 2008. Since then I spent a couple of years getting my head down in Uni before graduating and moving to Aberdeen for work in 2010. I bought my first place in 2011, and last year I finally had the time to have a project car again. I'll copy and paste my updates from the EsCos forum.

I’ve owned my Escort RS Cosworth since last September, but up until now I haven’t got round to writing out my project thread, so here goes. The car is now back on the road again, but I’ll start from the beginning and update this every couple of days.

As some of you will already know, I bought Si B’s 1993 Escort RS Cosworth big turbo model. I bought it because I had always wanted a big turbo version in red, and while some of the modifications weren’t to my taste, most of the expensive changes that I would have made (the AP’s, suspension and engine upgrades) had already been done.

After a few phone calls to Si the deal was done and a friend and I flew down to Bristol where we rendezvoused with Si who drove us back to Yeovil where his Escort was stored.

After a quick look around the car I took it out for a test drive, let the engine warm up and put my foot down to let it come on boost, then nothing but misfires! We limped back to Si’s house where it was clear that the car was massively over-fueling. We were all pretty surprised and didn’t have a clue what the problem was, especially Si who had used the car only the night before with no problems. After several hours of trying to source the problem, we still drew a blank. I called the deal off and went into the house to organise a hire car to drive home which Si had offered to pay for. We were literally 5 minutes from leaving when Si’s brother found a split air hose down the back of the engine which went into the inlet manifold. Once that was fixed, a quick test drive confirmed that all was well, so the deal was back on. Before setting on our way we did a quick oil & filter change as I was worried about all the unburnt fuel that was in the oil from the misfires, and I didn’t want to take the 600 mile drive home with it.

We set off from Yeovil at 17:00 on our way back to Aberdeen. We’d been up since half 5, and by half 1 the next morning we had got as far as Glasgow, so we stopped over at my parents’ place for an overnight kip before heading north the next morning.

Here’s a few pics from my folk’s driveway:

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We got back to Aberdeen the next day. After a long few days I drew the conclusion that it must have been my initiation test for Cossie ownership.
Last edited by AGAR on Sun Jun 02, 2013 8:16 pm, edited 2 times in total.
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Re: Escort RS Cosworth: C6 SSY Project Thread

Postby AGAR » Mon May 27, 2013 7:53 pm

Before giving my updates on what I have changed on the car over the past 8 months, it’s probably best to summarise what I had to start with. So here is the original spec and some pictures:

Body mods:
Morette quad headlamps, side lights body colour matched
Nomad Smoked rear light clusters, side repeaters and front indicators
RS500 Fog light grills
Debadged, destickered
Rear windows tinted in a dark smoke film

Interior mods:
Blitz Dual SBC Boost controller
Momo Race steering wheel
SECS Engine monitor
Pioneer I-Pod headunit
Directed rear speakers

Chassis mods:
Avo Coilovers
TCAs Polybushed
OMP Adjustable front strut brace
18”x9 Rota Fighters 255/35/18 Dunlop SP Sport tyres
Front AP Racing 6 pots with DS2500 pads and 330mm 2 piece discs
Rear Hi Spec Calipers inc handbrake with DS2500 pads and 300mm 2 piece discs

Engine bay mods and motor spec:
2.0 16 valve, 8:1 Compression ratio, 200 Block, standard head, cams, crank rods and block, Group A headgasket. AP Organic clutch kit

Engine built by Woodford Garage Motorsport.T34.63 turbo on 4x4 manifold.
L8 ECU with Motor Sport Developments chip – including Wasted spark coil pack driver, closed loop Lambda fueling and anti lag.

Newman alloy vernier pulleys, R&B Swedish Inlet manifold with separate vacuum distribution block with billet fuel rail, Siemens 83 lb/hr injectors, Aeromotive fuel pressure regulator, K&N air filter, Extreme 3” stainless steel exhaust including decat, Spec-R Heat shield, Spec-R Header tank, Spec-R Breather system including mirror image catch tank, stainless steel polished oil filler cap, Autospecialists washer bottle cap, Pro Alloy Power steering tank, Pro Alloy Radiator, Pro Alloy Turbo after cooler, Pro Alloy Intercooler, 3 bar MAP sensor on stainless bracket, Vibratech engine mounts

Samco boost and coolant hoses throughout, Alloy coolant swirl pot, Ford Motorsport plug leads and Focus coilpacks, chrome suspension top mounts. Stainless bonnet stay

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Re: Escort RS Cosworth: C6 SSY Project Thread

Postby boeb » Mon May 27, 2013 8:35 pm

Man that's sweet 8-) 8-) 8-) that's a dedicated car deal that 1. :lol:
Hahaha keep on laughing
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Re: Escort RS Cosworth: C6 SSY Project Thread

Postby andy-mac » Mon May 27, 2013 8:54 pm

very nice car there ritchard :D
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Re: Escort RS Cosworth: C6 SSY Project Thread

Postby Mel D » Tue May 28, 2013 1:12 pm

Nice and stands out in red :D
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Re: Escort RS Cosworth: C6 SSY Project Thread

Postby Stu/RS » Tue May 28, 2013 1:55 pm

Very nice Richard. Will keep an eye out for updates.
Love the wheels, but they need to be silver IMO. Just a personal preference ;)
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Re: Escort RS Cosworth: C6 SSY Project Thread

Postby AGAR » Tue May 28, 2013 6:18 pm

Cheers for the comments everyone.

The car now looks a lot different from above, I'm just typing out everything I've changed on it over the past 8 months - more updates to follow shortly 8-)
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Re: Escort RS Cosworth: C6 SSY Project Thread

Postby DALSY » Tue May 28, 2013 9:21 pm

Car looks great Richard, 8-) 8-) 8-)
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Re: Escort RS Cosworth: C6 SSY Project Thread

Postby davie 3 door » Wed May 29, 2013 9:36 am

Good to see you back Richard, Car looks well!! :D
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Re: Escort RS Cosworth: C6 SSY Project Thread

Postby Kevin_Mc » Wed May 29, 2013 11:35 am

looking forward to seeing more pics :D
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Re: Escort RS Cosworth: C6 SSY Project Thread

Postby AGAR » Thu May 30, 2013 8:57 pm

Thanks for the comments guys - really appreciate it. It feels good being back in a Ford, and being able to get back on here.

Here's the next update:

Having lusted after an EsCos for many years, I had a clear image of how I wanted the car to look, so I started to make the necessary changes:


The first big purchase was a set of Rondells (Engels) from Chris Barlo. They had recently been refurbed but were orange peely so I got them for a good price – cheers Chris. I also bought a set of Michelin Pilot Sport PS2’s but didn’t get them fitted until I got the wheel’s refurbed.

Before refurb:

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Sourced some new Rondell centre cap stickers and new centre cap locks:

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After the refurb:

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The next item was the SECS monitor. The original unit had a blue display and was mounted next to the stereo. It didn’t match the rest of the interior lighting (green) and it was difficult to see. So I swapped the display with Kev Anderson (KSA Cossie) and got Dave (Monster) to fab me up a mounting panel for where the time clock is – thanks guys. Here’s the before:



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During:

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After:

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I found that the leather seats, as nice as they looked, weren’t very supportive during high speed cornering. I was after a set of red hex cloth recaros, and luckily my mate came across someone who was wanting to swap his ones with a leather interior. The passenger seat and rear bench are in good condition, but sadly the driver’s seat has a few cigarette burns. I’ll get those seen to during the winter. Rsbuz has already supplied me with a huge section of cloth for the repair. I'll get that done during the winter when the car is off the road.

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With the interior out, I took the opportunity to clean up the floor pans and wet-vac everything. Can't believe how well it has come out! Thanks to my mate Rog for the loan of the wet vac:



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I also bought some carpeted seat runner covers out of a Scorpio which I thought would tidy things up a bit below the seats:

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That’s all for now.
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Re: Escort RS Cosworth: C6 SSY Project Thread - Updated 30.5

Postby paul-h » Fri May 31, 2013 7:05 am

Looks lovely! I've had a serious want for one of these for years!! Ha!
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Re: Escort RS Cosworth: C6 SSY Project Thread - Updated 30.5

Postby Stu/RS » Fri May 31, 2013 10:05 am

Great work Richard. "Devils in the Detail" as Dalsy keeps saying ;)
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Re: Escort RS Cosworth: C6 SSY Project Thread - Updated 30.5

Postby AGAR » Fri May 31, 2013 11:07 am

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Re: Escort RS Cosworth: C6 SSY Project Thread - Updated 30.5

Postby AGAR » Sun Jun 02, 2013 8:15 pm

Next update:

I had mixed thoughts about the morrette headlights, so decided to change to standard headlights, complete with standard clear sidelights (thanks to Karl for those). Once I’d sourced some standard lights, I had to buy some bolts and nuts to fit them, as well as some rear bulb holders which were missing (thanks to Paul Cos for those). I also really wanted a set of amber front indicators, so after several months of searching, I got some from Graham (Polaris Escos).

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The splitter and hockey sticks were originally gloss black, so I sprayed them with Simoniz Tough Black for the original matt finish. Unfortunately after 3 attempts at painting the splitter, it still hasn’t come out as well as the hockey sticks and the lower bib, but it’ll have to do for now.

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Here’s some before, during and after photos of the front end.

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Nice to find no nasty surprises behind the front bumper.

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I also changed the imitation nomads back to standard, as well as the side repeaters from smoked back to standard (thanks to Robbie for the side repeaters)

Before:

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After:

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Re: Escort RS Cosworth: C6 SSY Project Thread - Updated 2.6.

Postby Stevie8ball » Sun Jun 02, 2013 8:22 pm

Deffinetly much improved for the good nice lookin car bud
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Re: Escort RS Cosworth: C6 SSY Project Thread - Updated 2.6.

Postby davie 3 door » Sun Jun 02, 2013 8:48 pm

That looks great RIchard, your doing a fine job!
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Re: Escort RS Cosworth: C6 SSY Project Thread - Updated 2.6.

Postby andy-mac » Sun Jun 02, 2013 10:34 pm

looks so much better standard , it will be a cracking car when you have finished all the mods :D
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Re: Escort RS Cosworth: C6 SSY Project Thread - Updated 2.6.

Postby Kevin_Mc » Wed Jun 12, 2013 4:00 pm

it was nice before but it's properly stunning now :D
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