Scott D's next MK1 Escort Project

[ozstang65]

More recent upgrades, actually just getting around to adding some bits that i've had sitting around for ages.

Firstly, some video of last weekend's khanacross at Willowbank. Not a bad result, 1st in class and 4th outright, but I should have driven a bit better!

I've had these new hubs for almost a year now. The diff I bought a couple of years ago has 1/2" studs in it so I wanted to get the fronts the same. I ended up getting some Nice NS2710 studs for it so i had to drill & ream the hubs to suit, then press the studs in. Pretty easy really, no problems.



A bit of difference between the old and the new!



It gives an extra 10mm track each side too.

[ozstang65]

To carry on with this weekends work...

After the battery going flat at the khanacross last weekend, i decided it was finally time to install the voltmeter I bought a couple of years ago, along with a charge light for energising the alternator winding circuit. Turns out the light doesn't actually come on, but the alternator won't charge without it being hooked up so i'm just gonna leave it as is for now. At least I can see the voltage now, and as long as its 14, all's good.



Also got around to fitting the proper bumper brackets.



Along with giving it it's first wheel alignment in over 2 years (as the inside of the front right tyre was wearing a bit fast). Turns out it had about 7mm toe out so I wound it back to 1mm out.



All ready for Mt Cotton next weekend.

[gen mk 1rs2000]

scott those bumpers are same as yur alternator braket

[ozstang65]

You can make me up some magnetic carbon ones if you like steve

[gen mk 1rs2000]

[ozstang65]

Mt Cotton today. Hopefully the horsepower fairy can deliver some much needed grunt for tomorrow!

[ozstang65]

OK, the horsepower fairy didn't front so I had to drive a bit better. Not quite good enough for a pb, but only 0.08 off it.

[ratta tat tat]

[gen mk 1rs2000]

http://www.ebay.com.au/itm/RARE-WEBER-T ... t_44wt_922


c,mon scott
get with the program
if you are going to even get close to a basic pinto engine
you will need a setup like this
plenty of ppl have dreamed about a 200hp kent engine
but sadly never even seen a kent eng come close
to the grunt of a pinto

[ozstang65]

it's already got 200hp Steve! Problem is it's at 12000rpm and i haven't quite got it there yet

[ozstang65]

I've been busy with yard jobs recently and haven't really got around to much motorsport this year. Mid year Noosa Hillclimb is in a couple of weeks and I've decided to replace the exhaust before then, hopefully! I'll take the old system with me in case the new design fails me miserably!

After the engine refresh earlier this year I finally found out the specs of all the bits inside that make the noise happen. About a year ago I went searching for exhaust design programs and finally narrowed it down to pipemax by Larry Meaux

So armed with the program and all the numbers it spat out a result that i have drawn up and am now in the process of making. Firstly I've had to make a few jigs and templates to aid in the construction. I got most of the bits i needed from and the header flanges cut by Laser Central, created from my own drawing.

The design:

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The flange:

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A template for cutting up the mandrel bends as well as indexing to match up with the next piece:

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IMG_1945.jpg (62.06 KiB) Viewed 22437 times

[ozstang65]

And a couple of the jigs to help out. Making them on an 'as needed' basis!

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[stuart]

nice!! i like the template

[Peter Hackney]

You're a bit clever you are

I'm looking forward to seeing how the exhaust comes out.

[Danny M]

Secondaries are too long and too big and collectors need to be the same angle entry for both pipes

[ozstang65]

The collector branches are the same angle Danny, although the pic is a bit deceiving, i've used the same wrap-around template to notch both branches. The length and diameters are what the program calls for, although if they don't work i'll play with them a bit.

These are the parameters i'm working to:

Cam is a Kent BCF3
Power Band 2500 - 7000
Cam Lift(mm) 7.15mm Inlet & Exhaust
Valve Lift(mm) 10.47mm Inlet/Exhaust
Duration 284 Deg Inlet/Exhaust 250 @0.050"
Timing 34/70 70/34
Full Lift Inlet 108 Deg ATDC
Valve Dia 37.800 (in) 31.400 (ex)
Head Port Dia 34.400 (in) 29.400 (ex)
Runner Length (in head) 100.0 (in) 90.0 (ex)
Carb Body 120.0
Face To Butterfly 10.0
Trumpet 75.0
Manifold 70.0

[Darrin S]

Hey Scott does that Kent cam mean you can go Boating,Camping and Fishing in your Escort?

[Danny M]

Scott with a camshaft that small with little valves and that style of collector those pipes are going to be waaaaaayyyyyyyyyyyyyyyyyy ttttttooooooooo biiiggggggggg!!!!!!!!!!
Craig's aren't even that big and his is a very different engine to yours

[ozstang65]

We'll see how it goes! I need to practice my tig skills anyway

I should probably build a real engine one day and start going fast

Yeah, i almost looked up their catalog to see what i had..Boating, camping or fishing isn't very high on my 'need to do list' though!

[ozstang65]

This is what I got from the program (Chosen option coloured) edit: pipe sizes quoted are O/D

Cylinder Ignition Interval = 180 degrees 7000 RPM Hertz frequency = 58.3 Hz
Target EGT= 750.4 degrees C at end of 4 second 600 RPM/Sec Dyno accel. test
1.5990 Liters Exhaust System operating RPM Range from 5000 to 7500 RPM
--- 2-Step Equal Segment Length TRI-Y --- ( Low to MidRange RPM TQ and HP )
1st Y-Segment Dia. MM= 33.774 Length= 357.7 to 383.9 MM long
2nd Y-Segment Dia. MM= 36.949 Length= 357.7 to 383.9 MM long
Combined Total of all Segment Lengths= 715.4 to 767.8 MM long
--- 3-Step TRI-Y Specs --- ( Low to Mid-Range Torque and Hi RPM HP )
1st Y-Segment Dia. MM= 33.774 Length= 357.7 to 383.9
2nd Y-Segment 1st Step Dia. MM= 36.949 Length= 178.8 to 191.9
2nd Y-Segment 2nd Step Dia. MM= 40.124 Length= 178.8 to 191.9
Combined Total of all Segment Lengths= 715.4 to 767.8 MM long
--- 3-Step TRI-Y Pipe Specs --- ( Higher RPM Horsepower, possible TQ loss )
1st Y-Segment Dia. MM= 38.854 Length= 357.7 to 383.9
2nd Y-Segment 1st Step Dia. MM= 42.029 Length= 178.8 to 191.9
2nd Y-Segment 2nd Step Dia. MM= 45.204 Length= 178.8 to 191.9
Combined Total of all Segment Lengths= 715.4 to 767.8 MM long
--- Megaphone Collector Specs ---( Diffuser or Diverging Cone Shape )---
( TQ ) Diameter= 40.309 taper to 65.709 Best Length= 406.9 or 813.9 MM
( HP ) Diameter= 46.659 taper to 72.059 Best Length= 406.9 or 813.9 MM
H-Pipe= 406.9 X-Pipe= 1627.7 distance behind end of Primary Tube ends
Best HP/TQ Tuned Collector Lengths= 406.9 , 813.9 , 1627.7 , 3255.5 MM long
Worst HP/TQ Loss Collector Lengths= 610.4 , 1220.8 , 2441.6 , 4883.2 MM long
Note-> all Pipe Diameters are OD and based-off 1.588 MM inch Pipe thickness
---- Collector's Harmonics (includes Intermediate, Muffler , TailPipe) ----
1st Harmonic = 3255.5 MM long ... longest with Mufflers and TailPipes
2nd Harmonic = 1627.7 MM long ... longest recommended with Mufflers
3rd Harmonic = 813.9 MM long ... more bottom-end Torque
4th Harmonic = 406.9 MM long ... highly recommended , best Torque Curve
5th Harmonic = 203.5 MM long ... reduced Torque , more top-end HP sometimes
6th Harmonic = 101.7 MM long ... reduced Torque , not recommended