Popular Post Rhubarb77 Posted January 23, 2016 Popular Post Share Posted January 23, 2016 Here's some details on my MK2 Escort Denim pack project. I bought it pretty rough and had some minor rust cut out and repaired. I was undecided about going turbo with it but I'm going to bite the bullet. The car will remain the same on the outside but by the time I'm finished, will hopefully be packing close to 300atw on pump fuel & octane booster. The main parts aquired so far: Pinto engine Custom stainless turbo manifold Garret ball bearing GT2560R Sierra EFI inlet manifold YB Cosworth Pistons & rods Reinz standard YB head gasket YB distributor & phase sensor Holden LS1 coil packs with relocation bracket R31 Skyline diff, handbrake assembly, tailshaft end W58 Supra box FG XR6 turbo intercooler Discussion thread here //oldschool.co.nz/index.php?/topic/51642-rhubarb77s-1980-escort-denim-pack/ 11 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted April 5, 2016 Author Share Posted April 5, 2016 So still in the process of gathering the many parts required to make this happen. Spending a little on cosmetics to keep me going. Reverse eye leaf springs for the back, adj Capri coilovers on the front which I'll have back (from engineers) by the end of the week. Once it's low I'll be cheerin. Also some personalised plates. Can anyone make the connection? 4 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted May 9, 2016 Author Share Posted May 9, 2016 I finally assembled my Capri/ RS struts tonight after having the bearing and seal kits installed by a local mechanic. These are the same set up as the struts I had in my MK1. HSD 51mm 5kg coilover kit, Koni 86-1835SPORT inserts and some Noltec adjustable tops this time around which should get the front a little lower. I put one king leaf spring in the back to see how it looks with my JBW minilites. No point in doing both sides as the diff is coming out soon to swap for R31. Not too bad but needs some 1.5" blocks to get it looking just right ;D 6 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted May 25, 2016 Author Share Posted May 25, 2016 Struts are in! Only to have the RH Noltec adjustable top mount blow out on me. They have poly bushing that crumbles when it gets old. Like a good cheddar. A biggish order headed my way from GRP4 in Ireland. Roller top mounts (small hole) HD steel clutch cable, suited for pinto or YB conversions. Alloy block breather Anti tramp kit! Firewall gussets I also found a good block to drop the YB pistons into. A 1600 Pinto head is on the way which will be getting a cross drilled billet camshaft, Turbo spec. 450 lift, 280 duration, 115 lobe centres. Newman followers, Isky springs, port & valve job etc. We hope to have it bench flowing 200hp with 44 inlet & 36mm valves. What's the experience from putting bigger ex valves in the pinto 1600 head? I've been told up to 38mm with no unleaded seats and even then it may break through. 37mm with unleaded seats is possible but pushing it. A big order from Burton Power still to do. Hopefully my Diff guy will be back in action soon to shorten the R31 axle. Still so much to do 7 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted July 5, 2016 Author Share Posted July 5, 2016 Things are moving along steadily. I got my diff back yesterday (how big are the 28 spline axles!) We installed it today along with the king springs, new bushes etc. Next will be the fuel system and sorting out the rear brakes & handbrake. Fuel system is GRP4 alloy tank- 100 micron filter- Holley Blue lift pump- Proflow swirl pot- Bosch 044 pump, 3/8 Gates Barricade EFI hose, 40 micron filter, 4 x Siemens 630cc injectors, Turbosmart FPR800 fuel reg, back to swirl pot. It will be suitable for E85 but will do the initial tune on 98 7 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted September 8, 2016 Author Share Posted September 8, 2016 My motor is away being built but I still have this dummy block in the engine bay to keep working away with plumbing and clearances etc. Lots of small purchases over the past few months, AN fittings, turbo water lines, catch can. And I also got the LS1 to Pinto ignition leads made up. Only small steps but enough to keep up the motivation 8 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted September 8, 2016 Author Share Posted September 8, 2016 Fuel system bracket & components Dellow Conversions "Qik Shift" for the W55 Supra gearbox 9 Quote Link to comment Share on other sites More sharing options...
Popular Post Rhubarb77 Posted January 12, 2017 Author Popular Post Share Posted January 12, 2017 The Radtec YB MK1/MK2 Escort radiator intercooler kit has been fitted. 10 Quote Link to comment Share on other sites More sharing options...
Popular Post Rhubarb77 Posted September 16, 2017 Author Popular Post Share Posted September 16, 2017 The end is in sight. I've got the handbrake & throttle cables in at a Control Connections being modified. Car is booked for mid October to get custom wiring done. In the meantime I have a bolt in steel half cage to fit. It came from a 4 door so the rear legs need shortening. Then after it's wired, will get it tuned and on the road 20 Quote Link to comment Share on other sites More sharing options...
Popular Post Rhubarb77 Posted September 17, 2017 Author Popular Post Share Posted September 17, 2017 Final spec on the motor was Standard bore 2.0L pinto block YB cosworth rods & pistons Ported, big valve 1600 Pinto head (9.1:1CR) MLS head gasket & ARP bolts throughout Custom turbo grind camshaft, HD valve springs, Newman long pad followers YB under piston oil squirters, high volume oil pump & Peterson oil pressure relief valve Custom Go Pipes steam pipe manifold & 3" dump, ceramic coated 3" mandrel bent exhaust GT2860RS turbo Turbosmart 38mm external wastegate, FPR800 and Kompact bypass/BOV Romac harmonic balancer & custom trigger wheel Modified (1 tooth) YB distributor with phase sensor Sierra EFI manifold with 630cc Siemens injectors LS1 coil packs Haltech PS1000 ECU Haltech wideband controller 11 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted November 29, 2017 Author Share Posted November 29, 2017 So this happened yesterday There's still a bit more power to come after we swap the pump out. Turns out my Bosch 044 from ebay is a fake. New pump will keep the pressure at 58psi and hopefully see close to that magic 300hp mark 5 Quote Link to comment Share on other sites More sharing options...
Popular Post Rhubarb77 Posted November 30, 2017 Author Popular Post Share Posted November 30, 2017 19 Quote Link to comment Share on other sites More sharing options...
Popular Post Rhubarb77 Posted March 25, 2018 Author Popular Post Share Posted March 25, 2018 The car has been getting plenty of use and lots of compliments. Very happy with it. There were a few issues to sort out after some road testing. Oil pressure was low at idle because the engine builder used a cross drilled camshaft. Normally this wouldn't be a problem but I also had a YB Cosworth under piston squirter bar (piston coolers) and camshaft spray bar in the circuit which was too much for the standard pump. So he deleted the piston coolers and installed a Burtonpower high volume oil pump. Unfortunately the piston cooler assy doesn't fit a HV pinto pump and they don't make a HV pump for YB cosworth so the coolers had to go. Idle pressure then went from 8psi to 40psi. The engine builder said motor will be fine without the coolers if I keep it on E85.. I would have preferred a solid camshaft and piston coolers to be honest. Also some small changes to the exhaust system with a bracket off the bellhousing to brace the dump pipe and a flexi join after it. I also ran a 1/4mile on Friday night and was disappointed with 13.3 but it was at 111mph so it has an easy 12 in it. Just got to get out of the hole a bit faster and will also gear the car slightly higher with bigger tyres 11 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted March 25, 2018 Author Share Posted March 25, 2018 I've also grafted some fibreglass RS500 Sierra vents into a spare bonnet. It turned out pretty good and should help a bit with under bonnet temps. Still needs to be painted 5 Quote Link to comment Share on other sites More sharing options...
Popular Post Rhubarb77 Posted October 9, 2018 Author Popular Post Share Posted October 9, 2018 Hi guys. It's been a while since last post. The car has been performing great and I'm still getting out an about in it, mostly on weekends. There's always something on at the local track every couple of months. I really wanted to get back onto the forum after growing somewhat tired of facebook and all the crap it can add to this hobby. Anyway... as far as developing the car. I have learned that gearbox ratios are very important. The W58 I have is quite low in first and second gear and a bit of a gap to third. Typical of road ratios. Well, a 600hp XR6T i've not been able to beat at roll racing finally fell behind me the last time out because I rolled on in 3rd instead of 2nd. 3rd has much longer legs and I didn't lose the speed changing from 2nd to third. So I looked into close ratio gear sets for the W58 and turns out they are available. At a cost of around $4500. Needless to say, the CR gearbox can wait. But gee it would make a difference. Also, the temptation to add more power has gotten the better of me. I have bought a used HKS GT2835R-56T , it's a Garrett GT3071R with a back cut rear wheel so it fits in the T25 exhaust housing. Compressor wheel will go from 47mm-60mm 62 trim, to 53.1mm-71mm 56 trim and more importantly the turbine, from 54mm-47mm 76 trim to 56mm-53mm 90 trim. I'm aiming to add around 30 or 40hp so 330~340hp at the wheels. My current GT2860RS is pretty much out of puff @ 300whp. At first I was going to fit a 67mm GTX billet wheel, effectively turning it into a GTX 2867R. It could probably make that extra power but nowhere near as efficiently as the GT2835R-56T. The larger turbine is where the benefits will come from. A larger set of Siemens Deka injectors will also be fitted. Jumping from 60lb (630cc) to 80lb (840cc) I took it to the drags a few months ago and it went 12.75 @ 113 mph (2sec 60ft) . Hoping with the new turbo and tune to crack into high 11's. If not I will just live with it because any more power will result in problems like gearbox failure, clutch failure, cracked block etc etc. So here's a pic of the car launching when I ran the 12 with 205 60 13 rear tyres. I was only able to achieve low 13's with 185 60 13 tyres, as soon as the 205's went on it was into the 12's. I might put in some 3.45 diff gears with the 185 tyres which would work out about the same as 205's and 3.9. Cheers 17 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted October 24, 2018 Author Share Posted October 24, 2018 Turns out the turbo was in bad shape. Upon inspection it had noisy bearings and a chipped turbine fin so it was mailed back to the seller and I got a full refund (paid by paypal). On Saturday the diff gears were changed to 3.45 and I did a cruise session the following day. The new gears are an improvement. Speedo now accurate too 4 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted November 4, 2018 Author Share Posted November 4, 2018 Another night at Test n Tune to try out my new 3.45 diff gears. Long story short, I geared it too tall by running 205 tyres. Couldn't get it off the line very well and being frustrated with ordinary times, gave it a bit too much on my 3rd attempt and got terrible tramp which snapped my universal joint on the tailshaft Everyone was so chilled about it but I felt terrible holding up the night for everyone racing. I can't say I wasn't warned about these uni's. They're hollow not solid. Hopefully the shaft can be balanced, it did sustain a bit of damage from the accident. My diff builder recommended getting a XR-XF falcon tailshaft which he can modify to suit so I've lined one up already from an XF sedan. Believe it or not I've had GRP4 tramp bar (radius rods) brackets tacked to the underside of my car since I've had it on the road. It's about time I finished the job and put the bars in. Next time at the track should be a winner with 185's, a strong tailshaft and tramp rods installed! 7 Quote Link to comment Share on other sites More sharing options...
Popular Post Rhubarb77 Posted January 22, 2019 Author Popular Post Share Posted January 22, 2019 On 25/05/2016 at 21:39, Rhubarb77 said: Big update. Since the last post I got a heavy duty driveshaft made (modified XA-EA falcon tailshaft) and the anti tramp bars welded in. Diff gears are now 3.7- WOW, so much better than the 3.45's. A new GTX2860R GEN2 supercore has been slotted into the existing 0.86 turbine housing. All new custom alloy piping to hold more boost, allow a bigger filter and 32mm plumb back BOV. New tune coming up in the next couple of weeks. Gate spring pressure is now 12lb (up from 7) , 840cc injectors ready to go in and we'll be going to 25psi hopefully netting around 350whp! The car already feels so strong with the new turbo and diff gears. Cheers 20 Quote Link to comment Share on other sites More sharing options...
Rhubarb77 Posted February 11, 2019 Author Share Posted February 11, 2019 Dyno happened just over a week ago. I lost around 8hp from the weight of the new tailshaft haha. So after optimising the E85 tune with the new GTX turbo we got it back up to 300whp with the same boost pressure 20psi. Pushing beyond that the car began to lose fuel pressure so the boost is fixed at 20psi until I fit another Bosch 044 to make a twin pump set up. But looking at the results from when we pushed past 20psi, I will be lucky to get another 20whp out of it. Any more than that will require a bigger turbine wheel from the likes of a GT3071R which is an option even with the limited space available. The compact T04B compressor cover from a GT2871R can be used on the GT3071R (they have the same compressor wheel) and there's a T2 flanged Mamba turbine housing with Vband outlet that suits the full size 60mm 84trim turbine. I'm trying to resist the urge to go bigger. There would be some down sides- Traction problems, I'd have to ditch my 13x7 miniltes and AO48 semi slicks, then change diff gears again to suit 15" tyres. Boost coming on 1000rpm later in the revs. And of course the cost of doing it all 2 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Rhubarb77 Posted March 8, 2019 Author Popular Post Share Posted March 8, 2019 So I got the car out to the drags last week and was stoked to run a 12.4. The mph is the same as previous outings which is no surprise with hp being the same. But the better spool and take offs gained me 3 tenths of a second. Still pretty lazy 0-60ft so I'm thinking of getting some M&H 22" 8" 13" drag slicks and having a decent go after the next and final tune. I also ran in the Forced Ford Forum cruise last weekend at Lakeside All Aussie Day. Here's a link to a youtube vid from the guys in 51OBA. Enjoy 11 Quote Link to comment Share on other sites More sharing options...
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