Scott D's next MK1 Escort Project

[ozstang65]

A bit more progress today. Working down the line, next thing to be made was the megaphone collector. It expands from 1.625" up to 2.5" so I drew up the required development and started with a 2.5" pipe.

IMG_2123.jpg (51.33 KiB) Viewed 24818 times

Then just worked it in the vice, slowly pressing it together.

IMG_2129.jpg (48.43 KiB) Viewed 24818 times

A few hose clamps, tacked, then finally welded up.

IMG_2132.jpg (61.85 KiB) Viewed 24818 times

IMG_2133.jpg (51.09 KiB) Viewed 24818 times

[ozstang65]

Then some trial fits to get the megaphone outlet in the correct position under the floor to match up with the rest of the pipework.

IMG_2135.jpg (66.58 KiB) Viewed 24818 times

Lastly today some minor disassembly to allow me to weld out the joints.

IMG_2137.jpg (77.07 KiB) Viewed 24818 times

Not the flashest welds in the world, but i'm sure they're good enough.

IMG_2138.jpg (51.19 KiB) Viewed 24818 times

[Danny M]

[ozstang65]

Numbers are irrelevant, track times are the only thing that counts. 1000hp on tap doesn't count for @#$% if you don't know how to use it properly

[ozstang65]

Anyhow, back to the project at hand. The extractors are now welded out and i'm beginning to sort out the underside. I'll probably run this one straight out the back (much to the pleasure of some no doubt!). I don't run a watts link so i could run it over the diff, but i'll check out the under option in the morning. I'm making a 3.75" OD resonator to go immediately after the extractors which ends them at a supposedly tuned length. I won't have time to get the system coated and it may not be worth it if there's changes to be made anyway so i'll just paint the system with high-temp for now. It will be more of a direct comparison with the current system as it is only painted also.

Finished Extractors

IMG_2151.jpg (65.51 KiB) Viewed 24764 times

IMG_2153.jpg (50.08 KiB) Viewed 24764 times

IMG_2155.jpg (42.45 KiB) Viewed 24764 times

Onto the underside

IMG_2157.jpg (60.46 KiB) Viewed 24764 times

[Cam]

Great work, Scott. Admire your skills.

[ozstang65]

Thanks Cam.

Only a couple of pics today, the centre section is finished and the first couple of bends of the tailpipe are done. I've decided to go under the diff as the rear of the muffler was kind of pointing there already, and it makes it a bit easier to remove.

IMG_2164.jpg (51.62 KiB) Viewed 24704 times

Welds are slowly getting better too

[Mk1975]

I like nice work

[ozstang65]

Finally, done and run! Finished welding out the tailpipe thismorning and gave everything a quick coat of high-temp paint before installing it all. Along with that there was a small amount of other minor jobs done today and it's all ready for Noosa next weekend.

Last pipe to be made.

IMG_2170.jpg (65.38 KiB) Viewed 24650 times

Extractors installed.

IMG_2173.jpg (55.91 KiB) Viewed 24650 times

Mid pipe installed.

IMG_2180.jpg (59.32 KiB) Viewed 24650 times

Tailpipe looks close to the ground, but not many options when running under the diff on13's! It's higher than the front section which is the same height as the previous exhaust so finger's crossed it's all good. I'll find out next weekend.

IMG_2182.jpg (49.51 KiB) Viewed 24650 times

[ozstang65]

I probably should concentrate on getting the rest of it painted next..

IMG_2188.jpg (67.61 KiB) Viewed 24650 times

[Danny M]

The muffler should be right at the very back!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

[ozstang65]

I might need the room there to put another one if it's too loud!

[Neville Bertwistle]

Awesome stuff Scott. Not too many people would attempt to make their own extractors and exhaust so good on you for having a go.

[Danny M]

With the amount of hp yours has you will never need more than a single round muffler at the back

[ozstang65]

The mid-year Noosa Hillclimb is over for another year, and it was a huge success. 10 Runs in total and no major accidents made the event run extremely smoothly. Many thanks to all those involved with organising & running the event. I had 7 runs under my previous best time of 66.05, and finished the last run with a 65.14. Did the new exhaust help? maybe, but it certainly didn't hinder. It will be interesting to see how it does at Mt Cotton next time.

IMG_4057.jpg (48.81 KiB) Viewed 24442 times

IMG_4114.jpg (63.61 KiB) Viewed 24442 times

IMG_4297.jpg (57 KiB) Viewed 24442 times

Nothing much really to do to it before the next event which will either be a khanacross at Willowbank or the next Mt Cotton hillclimb on the 6th/7th September.

[jpayne]

Well done mate,
good work on the exhaust I bet its satisfying having run and done Ok with it. Especially having made not paid!
Keep up the good work

Justin

[ozstang65]

Thanks Justin, yours is coming along nicely too. There's always more to do than what you initially think! I may make another set of extractors based on the larger numbers from the program and see how they go. Different tracks might suit different extractors better than others.

[ozstang65]

I probably shouldn't have started this right now, but nothing like a bit of pressure to keep one focused. I've put in an entry for the teams regularity event at Lakeside on the 31st August so I've got 2 more weekends to get the car back together again. Like I've mentioned before, there has been very little focus on the remaining paint and panel, until now. Luckily the car's pretty straight and rust-free and i'm not going for a show quality finish so a few corners will be cut as I can already see myself at midnight on the 30th of August still finishing it off...

As well as a basic respray, I'm going to install these Mk2 guard eyebrows to give me a bit more space to install some larger tyres.

IMG_2335.jpg (42.83 KiB) Viewed 24367 times

I got this flange tool a while ago and it comes in real handy prepping panels for joining. It has a punch also to make holes for plug welding.

IMG_2338.jpg (40.97 KiB) Viewed 24367 times

IMG_2339.jpg (48.53 KiB) Viewed 24367 times

Once the new flare was ready, I used it as a template to mark the cutout (in 10mm from the mark).

IMG_2342.jpg (40.26 KiB) Viewed 24367 times

[ozstang65]

Which when removed, revealed the factory seal, attached only to the inner guard!

IMG_2344.jpg (51.55 KiB) Viewed 24366 times

A little bit of trimming and shaping later and its almost ready to be welded in. Tomorrow night job...

IMG_2345.jpg (47.23 KiB) Viewed 24366 times

IMG_2346.jpg (45.6 KiB) Viewed 24366 times

The original paint isn't too bad in most locations and the second paint job is very easy to remove. Shouldn't present too many problems prepping for the fresh coat.

IMG_2336.jpg (47.95 KiB) Viewed 24366 times

[jpayne]

good work on the arch, the edging tools a god send isn't it. My Favorite of the month...No wait the flaring tool, Oh the shop press, No the mig...Oh they are all my favorite.
Good luck with the deadline. Keep the photos rolling
JP