Petes Mk2 Escort 1600 Sports

[Petes mk2]

Bought this car 15 years ago after helping my son restore a 1971 Escort XL. Was being used as a farm run about. Got it home and used until Rego expired, then parked it up in shed and put rego on hold. Previous owner had replaced engine with 1600 Cortina motor which was a good runner. The old motor came with car so hope to put back in once reconditioned. Over the last 15yrs, have had numerous people call in wanting to buy after seeing parked in shed.

First job was to see if we can get motor running. Fuel tank out, drained and cleaned. Tank put back in, plugs out and spanner on pulley but couldn't turn motor over. After applying more pressure got some movement and finally turning over. Put in new battery, replaced spark plugs and hit key. Oil light went out and fuel made it to carb but no spark. Another hour and decide that we need to replace the condenser. Another try and she starts up straight away. Sounds pretty good considering she has been sitting for so long. Time to make some space in shed and start the big job of restoration back to how it was new.

[Petes mk2]

Have decided to start work on the original motor. A Friend of a friend works for a motor reconditioner and has kindly offered to help. So packed up all the bits and pieces and off to his place to access what is needed to be done. After pulling apart and cleaning we have a list of things to do and parts to buy. Block looks good but needs to be bored out, Crank just needs a polish. Had two old pistons and two new ones in it so don't know what was going on. To buy, set of pistons,rings, oil pump,water pump, clutch kit, timing chain and a few other bits and pieces. Fly wheel is going to be lightened. Cam is getting reground to a mild sport profile.

Head is in a bit of a sorry state with all exhaust valves badly burnt so four new valves and hardened seats put in. Also going to port head for some extra power.Time to start spending some money.

[Petes mk2]

Finally made some space in shed and have a work surface and cupboards for storing parts in. Car is going to be repainted so plan is to get it to rolling shell state. Time to start removing fittings and find out what is hiding underneath. Quarter bumpers off, indicator lights out, Grill removed which is in good shape just a bit faded. Headlight buckets out which brings to light the first major case of rust. Lucky it is just on the right side.

Started work on the back and removed rear bumper,  tow bar  and cleaned out boot. Spare tire well has a load of bog which once removed shows more rot. Going to need a panel beater I think. I'm sure there is more as have seen signs of other bogged areas

[Petes mk2]

Finally got round to removing all the seats, carpet, door cards, kick panels etc and are now $3.25 richer. Only found three more areas of rust that will need to be repaired. Two in the floor pan in front of back seat. Not a big area and should be easy to replace. The other area is in the side wall of the passenger foot well. This might be a bit harder to fix. Most of the floor pan is covered in sound proofing which looks to be in good order. Have cut this back around areas of rust and it looks like new underneath. Some surface rust which just needs to be treated with rust converter.

Also decided to take overriders of bumpers which proved to be harder than expected. Two screws shared off and had to be drilled out and tapped. The others took a lot of patience. Bumper are matt black and will need to be refinished. Not sure if painting or some other finish is needed. 

[Petes mk2]

Finally back on the job. Took out weather strips and retaining clips from doors Removed divider channel for glass followed by glass which seems to be in good shape. Next took out quarter windows. After cleaning they looked really good. Glass had a sort of lime scale around the edges which was quite hard to remove. Next took out the regulators, cleaned them up , ready for putting back in later. Found quite a bit a bit of rust in the bottom of the doors and some of the drain hole were blocked up. Not sure how to deal with this. Will attempt to start a Project Discussion page as have a few question that someone might be able to help me with. Cheers

[Petes mk2]

Not sure how to link this with Project Discussion so hope this works

https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

 

 

[Petes mk2]

Firstly, Thanks for the helpfull advice given in the Project Discussion section. Went to Safr R Brakes who were very helpfull and put me on the right track. Have had brake shoes relined and collected new wheel cylinders. Have fitted these now and bleed the system. Everything seems all good. Next step is to start working on getting the engine and gearbox out. Started by removing drive shaft. While unbolting rear flange I notice a small amount of oil come out. Not sure if there is a seal that needs replaceing. will look into this. Have left a couple of question  about motor removal in Project Discussion

 

https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

[Petes mk2]

Its been a while since I last posted so have managged to get a few things done. Have removed tail lights and number plate lights and labeled all wires. Also taken pictures to help me put back together. Next remove that part of the loom up to where it conects with main loom.

Also removed all the remaining glass without breaking any. Rubbers for side windows look to be in good shape but the front and back ones will need to be replaced. Found a few rust spots around the window edges. Hopefully not to hard to repair.

[Petes mk2]

Now to start on removing everything connected to the engine before removal. Had to cut of exhaust off manifold as whole system was just welded together. Drain coolant from radiator and block, then remove radiator and fan. Unplug wires to water temp and oil pressure sensors. Disconnect starter motor cable. Next remove accelorator cable assembly and remove carb. Tag on carb reads (Weber 771F AA A 6J 2 ) will look up to see if this is what I need for motor I'm putting back in car. Remove heater and vacuum hoses. Disconnect speedo and clutch cables. Remove both intake and exhaust manifolds. Out with distributor. Unbolt gearbox support cross member which looks a bit the worst for ware. Almost forgot to take outgear lever.

Next out with the motor slowly slowly. Please I got  the tilting attactment for crane as you have to apply a lot of tilt to clear front of car. Looks like we have got a 1300 motor. Hadn't checked numbers before I took out motor and was under the impression it was a 1600.

 

https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

[Petes mk2]

Slowly catching up with where I'm at now. Should have posted more regularly.

Next to come out was the speedo cable and clutch cable. not to hard once you figured out how they are attached  Brake booster was next. Everything looks to be in reasonable condition. Booster will need a good clean and paint. Now to remove the front  loom. Have labeled all the ones I know but there seems to be a lot of wires with no home. Some may be for the spotlights. I'm sure it will fall into place if I lay it out on a table and clean it up.

While doing this I've got a couple of queries that I will put on my Project Discussion page. Any help will be appreciated

Cheers

https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

[Petes mk2]

Still on the job just taking a bit longer due to other projects. Have removed all the brake lines and calipers along with the dual fuel lines, one return line. Documented all attachment points. Will replace as a bit smashed up.Thinking of using 10 mm truck air hose which is a similar type of hard plastic. Will have to check if can be used with fuel. Remove fuel tank on which you can see blue truck air line which I used for a repair when I cleaned out tank. Had great trouble getting old fuel line out of tank when I cleaned it.

Degreased and cleaned engine bay. Not looking to bad

 

[Petes mk2]

Now onto the interior, under the dash. Took off all plastic covers and started unpluging everything and labeling as I go. One or two loose wires without a home but i'm sure I will be able to sort out later. Finally got loom out except wires running to interior light. Taped a pull wire to the end but unable to pull through so must be clipped on under head linning which is still in place.  Finnally just cut them off and will put a connector on when it all goes back together. Next took off the dash pad which has a few cracks in it. If anyone can suggest the best way of repairing this could they leave a reply in the Project Discussion secton listed below. Also looking for someone to check over my manual gearbox in Christchurch. Cheers

https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

[Petes mk2]

Have got a bit done since last post. Removed heater unit and dash vents. Removed pedal box which then allowed me to take out the insulation up against fire wall. This is not in very good condition so not sure what I can use to replace it. Any ideas, let me know in my Project Discussion. Next removed indicator storks an ignition-steering lock. Decided to leave window wiper assembly in place.

Ready for he panel shop. Took photos of all black paint areas for reference when getting it painted. Also photo's of all rust-dent areas that require work. Its going to take a while I think. Onto the triler and off to Christchurch. Had to unload onto footpath and then push across four lanes of trafic but finally there.

https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

[Petes mk2]

Have been getting some work done on the motor that came in parts with the car when I bought it. Block has been bored out 40" and planed. Crankshaft just needed polishing and put back in with new bearings and seals. Next put in cam followers which have had a surface grind. The cam has had a light sports grind and put back in. With all timing marks lined up new timing chain is fitted along with new tensioner. Timing cover and oil seal fitted. Looking good

Next we fitted bearing shells to conrods and caps. Followed by fitting new pistons to conrod. Then we gapped the rings and fitted to pistons. Next pistons inserted into block and  and caps put on, all with plenty of oil. Torque down all bolts and we are done.

Next onto the head which has been planed and had new hardened valve seat put in. We then ground valve seat and valves ( needed 4 new exhurst valves) and checked fit. All good so fit stem oil seal, springs and collets. Head has been ported so just have to match to intake manifold.

Oil pump has been refurbished but need to get a new water pump, petrol pump and distributor. Also need a set of head bolts which ar hard to find in NZ.

Good to be putting things back together. Should be a nice motor when finnished

Project Discussion https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

[Petes mk2]

Called into the panel beaters for the first time afher droping car off to see what progress had been made.  He has fitted the two patch panel i supplied to fix the wheel well area which was badly rusted. Panels didn't quite cover area of rust so had to do a bit work. Has repaired areas of rust around window edges and also ends of sills plus floor pans.  Has removed rusted section from front guard, headlight area. Will be intersting to see how he repairs this area as there is quite a bit of rust.

Project Discussion https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

[Petes mk2]

Went back to see panel beater and see what progress has been made on rusty areas. The front right guard has been fixed, front vallance has had all the dents taken out. The rest of floor pan has been repaired. When it came to the doors, there was a lot of rust on the inside that was progressing to the outside so he has cut the bottom off outside skin and repalaced. I need to start thinking about what colour i'm going to paint her. Have been told present colour is Olympic Blue but not sure. Have left a photo of vechile tag on discussion page if anyone can help with deciphering tag. Someone else said present colour is not a 1600 Sport colour. What do you think?

Have also refurbished petrol tank which was in really good condition inside.

Project Discussion https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

[Petes mk2]

Finally got back to working on engine. Installed oil pickup and then sump. Have been painting engine as we go trying not to paint aluminium parts or frost plugs. Next fitted the head and torqued down. Had to check that I had the right pushrods so did a temporary fit of rocker shaft. All good so finished fitting pushrods and rocker shaft.

Next we fitted the front pully so we could turn the motor over and set the valve clearance. Once that was done the intake manifold, which has been ported, was fitted. Then onto putting in the two remaining frost plugs. Finally with the number one cylinder at TDC and following the instruction we fitted the distributor. A new fuel pump also in place and tappet cover on.

Not looking to bad. Just a few more small thing to buy and fit such as temp sensor, oil pressure senor, themostat and of couse spark plugs.

[Petes mk2]

Motor pretty much finnished. Brought all of the small parts and a selection of nuts and bolts. Was quite surprised at the price of things, especially spark plugs which I haven't bought in a while. Fitted water pump and pully, spark plugs,temp sensor, oil pressure sensor. Next installed thermostat and housing. Half filled oil filter and screwed on. Was told I needed to use and oil that contained zinc to minimise cam ware and possible failure.  Pushed emission control valve system into place. Just have to find a dip stick.

Removed engine from stand with crane and fitted lightened fly wheel. Almost forgot engine plate. Torqued up. On with the clutch disc and pressure plate after making sure we had put some grease around spiggot bearing. About as much that we can do at the moment. Onto the ute, wrap up for trip home.

Safely in the back of shed waiting for return of car. Much thanks to Rod Clark from Ashley for helping me build this motor. A weaith of knowledge.

Project Discussion https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

[Petes mk2]

Its been a while since I called in to see how panel beater is getting on with removing rust and sorting out panel work. Car is looking good. They have sand blasted underneath the car which found a couple of rust areas in chasis which need a repair. Underneath has then been 2k primed  and is ready to have a  stone guard coating applied.

Engine bay has been sand blasted and is waiting to be primed along with the rest of outside of car. After much debate I have decided to keep car the same colour, Olympic Blue. Really starting to like this colour. Still a bit of work to be done on inside of car  but painting can't be to far away

Project Discussion https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/

[Petes mk2]

Body work nearly finished. Small repair to heater bowl done. Still some work to do on passenger door which is not closing properly after having roll pins replaced. May have had some impact damage in the past. Have also had the colour matched for final paint colour before all original colour was covered up with primer. Getting closer to paint booth all the time.

At home have been going over parts and getting ready for reasembly and also decided that my open shed needed to be closed in for when car comes home so working on that.

Project Discussion https://oldschool.co.nz/index.php?/topic/84912-petes-mk2-escort-1600-sports/