The "Project ASBO" XR2 56k Beware

[Gooey]

After owning lots of Ford machinery both old and new, I ve gone Old Skool again and bought a Mk2 XR2. It was origionally Turbo'd pushing out near on 200 bhp but whilst driving it home, It decided to melt a piston   

It did look like this but alot has changed :lol:









The car wasnt built to a standard I liked so the project begun. It was completly gutted inside and out and basically all the bad bits of which there are lots are slowly been put right as and when funds allow 

This was its state 2 weeks ago 







The car was full of Autometer guages but these have been sold and I ve spent just over a grand on a set of Defi's from Japan including a HUD 









The car had a Mk3 dash installed but it looked gash so I binned it and my brother has modded a Mk2 dash although you can barely recognise it anymore. I picked it up last weekend after getting it flocked 





New Mondeo push button start







Next up were the wheels as I didn't like the Wolfrace ones that were on it.I bought these off ebay from Germany which cost in total with postage.......... 104 of your finest English pounds 



Sent them away to be refurbished and they came back a week later looking like this




They ve since been wrapped in a set ot Toyo T1-R's and now sit in my mothers dining room looking very Carlos Fandango  LMAO

[Gooey]

The engine choice was always going to be a Duratec but I hadnt planned on the turbo lump expiring as soon as it did so a 2 litre Zetec is currently been built up to be dropped into the engine bay

Modified Engine Mount



Nice Shiny Manifold although I have some Heat resistant material to wrap it in



Inlet Manifold which is currently having its ports opened up



then these should work a treat, Crackle Black Jenvey Throttle Bodies with Emerald Management



The next find was once again German Ebay and comes in the form of a rocker cover bearing a certain old skool feel to it as it sort of resembles a BDA one



Fiesta lights on whatever I ve owned including the ST have always been bad so I ll be running Xenon's FPMSL



Random bits from Ford



Gearbox is a proper nightmare. Im using the gears from a RS1800 as these are best for acceleration, a late spec zetec escort bellhousing as the starter motor is located at the back allowing my manifold to run under the front nicely and finally the LSD out of a Series 2 RS turbo as pictured



Latest pics of the flocked dash







And starting to install the guages





Seats have been modifies and put back in the car properly



Cage has been removed and had extra bars welded into place



Then refitted into the car

[Gooey]

I got a inlet manifold from ebay a while back now but upon fitting it up to the head, there was quite a bit of metal fouling where air should be going so out came the dremel and now there all nice and smooth.





Wrapped my very blingy looking manifold in some thermotec wrap, took me fooking ages and my hands itched like fook afterwards with the fibreglass dust that was on it.
Bloody snap straps I got were way too big so I need to get something else now to hold it in place properly.



When the inlet and head were finished machining, we tried the throttle bodies up against the inlet and I very nearly wet myself with excitement




Rocker Cover went from looking like this



To this



My paint sprayer did it for me in the end with the Orange detailing





Vernier Pulleys were anodised red but have now been painted the same orange as well



Wing mirrors were Matt Black but have now been coated in paint to match the rest



And my Porn horn which has been on my last 3 cars hasnt escaped the spray gun either

[Gooey]

Yesterday we spent most of the day breaking down 2 gearboxes and rebuilding one out of them.
The RS1800 internals were picked as being better than the Escort GTi ones for better acceleration so both boxes were stripped down.









The RS1800 internals were swapped into the Escort bell housing meaning the starter motor could be located at the back of the bell housing allowing better clearance for my spangly manifold.



The Series 2 LSD was also fitted into it and will be bolted to the engine ready to be dropped into the car

Engine was sat in the corner looking very glam and I nearly shot my bolt when it was uncovered







We also removed the fuel cell  to begin tidying up the pipe work and repaint the brackets as parts of it had to begun to rust

[Gooey]

Well we got a little bit more done today.

My light weight TTV flywheel



And fitted to the engine



RS Turbo clutch



Completed Engine and Gearbox Build up



I attempted to fit the wing mirrors today and after lots and lots and lots of swearing, they finally made it onto the car



Had a go at crackle black painting my washer bottle as well, dont know of the final outcome as yet, left it all day today in a really warm room and finished spraying the one side I couldnt get too tonight.
It currently looks like this though

[Daz-cos]

looking proper sex wee mate!!! the attention to detail is first class!!!!

[tabetha]

A lot of work there(and money) should be really good, is it an everyday car ?
I see you are using 36-1 pattern, are you using Cl + EGT with the emerald ?
tabetha

[Gooey]

A lot of work there(and money) should be really good, is it an everyday car ?
I see you are using 36-1 pattern, are you using Cl + EGT with the emerald ?
tabetha

Wont be an everyday car although the urge to use it everyday will be tempting.

Forgive my stupidity but what is the other stuff you ve asked?

[mini]

remember to get some rubber around them holes in the bulk head keep the good work up

[RST-Steve]

Fook me that looks stunning!!!! 

The wheels, dash, rocker cover..... oh and porn horn etc etc all spot on  didn't realise eBay Germany could be so useful lol!!

You'll have to bring this to a meet when its all done and on the road!! 

[Churchy]

Pete, your a bloody nutter when it comes to your cars! You do have cool cars though

Can't wait to see it!!!

[tabetha]

I just noticed that you are using a EMERALD ecu, and the rear of the flywheel is 36-1 tooth pattern, for the crank position, for the ecu.
I was just asking as to whether you were going to use the closed loop(lambda) and with the EGT that the Emerald can do ?
Is it a K3 ecu, as just bought one myself, are you having it mapped at Daves(emerald's), in Watton ?
There are some FREE upgrades just done to the software that can be downloaded that karl was telling me about, and a few more on the way!!
tabetha

[matt]

Excuse me while i wipe the drool from my keyboard.  retyu7uiolohgferyetul,mnertl,56t78oikjiuh3

I feel a mag feature coming on.
Gooey PLEASE put finger to keyboard and write an article on this for the Norfolk group Newsletter. We NEED to be kept informed

[Gooey]

Excuse me while i wipe the drool from my keyboard.  retyu7uiolohgferyetul,mnertl,56t78oikjiuh3

I feel a mag feature coming on.
Gooey PLEASE put finger to keyboard and write an article on this for the Norfolk group Newsletter. We NEED to be kept informed

Maybe, I want to finish it first


As for running closed loop, I spoke to my engine builder today and he said its something we can do in the future, I think he wants it out of the way almost as much as I want it on the road 

And yes, once its on the road, I ll make it to a meet 

[Gooey]

Things are moving along very quickly now, I got there this morning to find my engine hanging on the crane and the car pointing up in the air  :shock:



Within an hour we was like this 



We trial fitted the manifold on to see how much clearance we had



and to be honest doesn't need much modding at all considering it is designed for a focus



Next up we fitted the throttle bodies, fuel rail and regulator 





We wondered if the strut brace would clear the bodies and lo and behold, it did 





It was deemed too normal and restricting to the bodies as it was tight for clearance so it will be cut and a new strut brace designed to run between the head and injectors 

Fuel cell re installed with freshly painted bits 



Couple of pictures of the Heads up display mounted on the dashboard





Few more pics of the dashboard, one of the front with a few more colour co ordinated bits



and a few of the metalwork behind  :shock:

[RST-Steve]

Looks like its coming together rather well!! 

Gonna be a proper little beast 

[Fireball]

Absolutly amazing looking motor there, can't wait to see that in the flesh. Best of luck with the rest of it and please keep the pictures coming.

(Now, does anyone know where i can sell a kidney? Well looked after/nearly new condition, few years of University abuse, will swap for T3'd Fiesta RS)

[Churchy]

Can't wait to get a go in this mate!!!

[Gooey]

Done a bit more to it today, the wiring has been left until its back on 4 wheels but...............

the rad and fan are in



One custom made strut brace, just needs crackle blacking now



Freshly painted Oil cooler



Porn Horn fitted



Manifold finally finished



Cleaned up a old set of standard lights and hammerited them black, they ve come up surprisingly well



Also fitted the Coilovers today and have started stripping down the brakes to be repainted. The exhaust and brakes will hopefully be on the car when I go up next weekend so it will be a chance to crack on with the wiring 

[Gooey]

Well the wiring has been started this weekend.

Loom in the process of been made up 



Fitted the poly carb windows, what a pain in the ass  :?:



refitted the fuel cap in the window as well



The radiator/oil cooler/fan set up



Found a problem with the front end................ or lack of it. I cant mount the standard headlights or indicators as there isnt anything to mount them on/too.




Cutting up a new panel to rectify the problem now




Escort Cossie Calipers and the RS2000 discs



Plan is to now rub the calipers down and hammerite them black, I have the spacers so will be fitting Escort Cossie discs and pads 

Most of the weekend was spent doing various bits of wiring, the Emerald ECU is wired and so are the Defi's and switches    :shock:    :shock:    :shock:



New front end evil Look  :evil:  :evil:  :evil:  :evil:  :evil:

[Daz-cos]

coming along nicely bugsy a ride in this when its complete!!! 

[RST-Steve]

Looks a proper little beast matey, that dash looks spot on

[Gooey]

Placed my final order this evening for parts. The car was supposed to be finished in 2-3 weeks but the Orange Samco hoses are going to be 6-8 weeks, Im gutted to say the least 

[Churchy]

Why use Samco, Roose motorsport are soo much better!!!

Doesn't mean you can't use it till they get here does it???

[RST-Steve]

6-8 weeks!!! Thats a custom job then obviously?? Worth the wait tho i bet

I've got a full set of Roose on my car but i've never really read anything negative about Samco's tbh