24/9/2001 - Finished, MOT'd and Running (well in a fashion anyway!)

In the last two months I have practically lived in the garage (apart from a week at Skeggy in the rain and going to work).

Here's what I've been up to:

In the Engine Bay

I dismantled the 1300GT engine which I was going to put in the car but decided that it really needed a re-bore. I had intended to save the 1600 crossflow engine to build over the winter but I have ended up using this in the car.

Before fitting it I removed the head and replaced it with a big valve version I had bought second hand, I cleaned and polished the inlet and exhaust ports and the valves themselves before grinding these in. I removed the sump and checked the bearings, crank etc and turned the crank with oil down the bores to check the rings. I polished the piston tops and degreased the block and sump before painting them. I then re-fitted the head, using a new gasket set.

I dismantled the carb off the 1600 and realised that the one off the 1300GT was in better nick so I cleaned that up instead.

I took the gearbox box off the spare car which I have and cleaned that up and painted it and also took the propshaft off my old Mk2 (which was an 1100 so had the preferable single piece prop on it). This was also cleaned up and painted.

A friend lent me his engine crane and this was used to lower the engine and gearbox together into the car. Yes, they can be fitted together but I recommend you have a spare pair of hands (cheers Col!) to avoid damaging the paintwork in the engine bay. New Plugs, filters etc. needless to say were fitted.

I had the brake servo and bracketry blasted to remove the rust and painted this up before re-fitting. Unfortunately the servo no longer worked after this - so watch out if you try doing this.

I also did the same to the air filter assembly which was painted using Ford Electric Blue out of a spray can.

I bought a new Ashley exhaust manifold and twin box system from Rally Design and 'fitted' that. Unfortunately the mountings don't line up on the rear box so I have rigged a temporary bracket up and intend taking it to an exhaust centre to get something more permanent sorted out.

I had a problem when it came to fitting the clutch cable - I had put the release arm in back to front so I had to remove the gearbox, prop etc to swap this round which was no easy task on my own. I didn't even attempt putting it back on, on my own, having got trapped under the car, my brother helped do this later (cheers Pete).

Underneath

Cos I didn't have the necessary tools I had all new brake pipes made up at a local motor factors - not cheap though, wish I had bought the tools and done it myself. New brake hoses were also fitted when banging these on. I used 'P' Clips to secure these as the original fixings were past their best. I also used these to fit the petrol pipe on.

I re-fitted the hand brake cable and the front calipers which were treated to a new seal kit and a re-paint prior to fixing on.

I also painted the petrol tank and refitted this which took ages because the repair panel fitted in the well in the boot did not have the holes for the bolts for fixing this in it so it was a bit of a job.

Bodywork

I spent a couple of days removing sanding marks from the paintwork, having used too coarse a grit to 'flat' the paintwork after spraying. In the end I ended up getting an electric mop from Handi-hire (cheers Tom/Dave) and using rubbing compound to polish up the paint.

A tip here - KEEP AWAY FROM THE EDGES when using this. Where's that touch up!

The exterior trim and badges etc were put back on after a good fettle and I got hold of a new grill from a guy in Surrey through the ads in Classic Ford (always worth a look).

The front and back lights and indicators have all been cleaned and polished and refitted and new number plates have been bought and fitted.

I have cleaned and polished the bumpers the best I can for now but hope to get these re-chromed it the near future.

Re-fitting the windows was 'interesting'. The sides ones were no problem but the front and back ones were an absolute pain. Thanks to the wife for help here (there's always a first time!)

Interior

I have fitted early black vinyl seats to the car, the ones with the checked effect (Twin Cam?). I have used a second hand carpet for now which I hope to replace longer term and have fitted the door and rear side panels off the door car as these were in good nick. I spent at least a day cleaning the overspray off these (from the body spray job) which taught me a good lesson to pass on. REMOVE STUFF YOU WANT TO KEEP MINT FROM THE GARAGE BEFORE SPRAYING.

I have fitted a mint dash top and cleaned up the original clocks before re-fitting these. I tidied everything up using Armorall which looks good.

The original steering wheel has been put back for now and this has been treated to a new leather cover. (Note for Santa - Springalex please)

The original headlining was removed because it was ripped and the one from the donor car has been put back in it's place. It does need some work later though to get it fitted perfectly - I lost my temper trying and gave up.

I have fitted inertia reel seat belts from my Mk2 cos these were in good nick. The original sun visors cleaned up nicely (with normal washing up liquid) and these have been re-fitted.

MOT Time

She failed! I couldn't believe it. Anyway it wasn't that bad - just a perished bush on one of the back Billies. Bad news is I couldn't get a replacement bush so I've had to put standard shocks on for now. Anyway the ticket runs out September 12th 2002 so I'm over the moon.

Big Thanks for help during the last month or two to:

Dave from the RS Garage for helping me get the car running after I got the distributor 180 degrees out (yes it can be done - watch for this! - I wasted about a day).

Pete (bruv) for helping me put the box back on when I got the clutch lever back to front.

Mark for helping me get the engine and box out of the donor car and for not laughing when I cut my leg unlike the wife. NOTE: PUT SCRAP EXHAUSTS OUT OF HARMS WAY.

Dave from the RS Garage (again) for giving the car the once over after the MOT. Dave probably saved me from a possible major setback or disaster. First he found a petrol leak which was causing the stuff to drip on the distributor - could have been fatal! Next he found a washer floating about in the air filter - again could have made a nice mess if it had got into the engine. Dave I can't thank you enough. I RECOMMEND THAT YOU GET SOMEONE TO LOOK AT YOUR MOTOR WHEN YOU FINISH BUILDING IT. IT IS AMAZING WHAT YOU CAN MISS.

If you need any work doing on your Escort get in touch with Dave - I can't recommend him enough. His web site is www.rs-garage.8k.com or just click here.