escortrs2000.co.uk Posted March 4, 2013 Share Posted March 4, 2013 (edited) This week I decided its about time I started a build thread on my 1989 XR3i Cabriolet. It all started in November 2006 when I swapped my 1996 Escort RS2000 16v for a 1989 Escort RS Turbo. I already had a project in the form of a 1988 Fiesta XR2 which was almost complete. I'd wanted an RS Turbo since my early teens so this was an offer I couldn't refuse. The RST had a few months MOT left so the plan was to finish off the XR2, poodle around in the RST then start rebuilding it once the MOT ran out. Well as with all of these things, the MOT ran out and then my circumstances changed. My wife and I were offered amazing job opportunities 200 miles away in London so we took them and moved. I finished and sold the XR2 to fund the move and put the RST in my parents garage with the intention of tidying it up whenever I was home. Over the next few years I collected all of the parts I needed to rebuild and upgrade the RST but as I got further in to the build things changed again. Rust and time were against me. I got offered a 1989 MFi XR3i cabriolet by my brother in the summer of 2010 for really low money. It was solid throughout and more importantly an absolute bargain. The new plan: reshell the RST into the cabriolet. Here's a few pics of how I got it: A quick wheel change, much better: So, I stripped the RST shell and sold it on. I fitted the '90 spec front bumper and Recaros from the RST. Then with the proceeds of selling the shell, I had the XR3i re-sprayed to make it minty mint: Edited March 4, 2013 by escortrs2000.co.uk Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted March 4, 2013 Author Share Posted March 4, 2013 I then began the task of cleaning up and painting all of the running gear: Once it was all freshly painted, I got it transferred in to the cabriolet and got an MOT. I drove it like that for the summer: Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted March 4, 2013 Author Share Posted March 4, 2013 At the end of 2011 she was parked up. Now the RST engine rebuild and transplant coupled with the EFi conversion began. As I already had an MFI RST engine with a few thousand miles since the bottom end was rebuilt I did things slightly diferent. Instead of an EFi bottom end with a CPS hole I opted for a bottom pulley and CPS mount from a CVH Sierra (36:1 trigger wheel). This is a tight fit (impossible with the engine in place) but will work fine : Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted March 4, 2013 Author Share Posted March 4, 2013 Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted March 4, 2013 Author Share Posted March 4, 2013 And that's where we stand today. To finish it off for use in the summer I need to sort out a fuel leak, sort any issues starting it, tape the loom, re-fit the dash and tighten the front running gear. Current spec: Engine 1.6 CVH EFi Ported and polished head Stage 1 T3 turbo & -31 actuator Airtec Front Mount Intercooler Airtec aluminium radiator Black silicone hoses all round Group A induction filter Mongoose stainless steel exhaust Custom EFi loom OFAC management Beige injectors Adjustable fuel pressure regulator Powerchips 195 chip Small turbo EsCos MAP sensor Running gear: Koni adjustable dampers AVO -35mm springs Flo-Flex polybushes RS Turbo hubs, Anti-Roll bars (Front and rear), tie bars and wishbones. Brakes Front: Escort Cossie callipers with Sierra Cossie 2wd disks, Ferodo DS2000 pads and Goodridge braided hoses Rear: Sierra XR4x4 callipers with Sierra Cosworth 2wd disks, Ferodo DS2000 pads and Goodridge braided hoses Lee Quote Link to comment Share on other sites More sharing options...
chaz Posted March 6, 2013 Share Posted March 6, 2013 Nice mk4 mate, I like that Quote Link to comment Share on other sites More sharing options...
Guest chris_g99 Posted March 11, 2013 Share Posted March 11, 2013 This is my plan for my MK4, just got to find a suitable doner car. Nice job you've done mate Quote Link to comment Share on other sites More sharing options...
Guest Gavxxx Posted March 16, 2013 Share Posted March 16, 2013 nice Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted March 21, 2013 Author Share Posted March 21, 2013 Cheers lads, look forward to getting it all running and ready for the summer now. Haven't driven a turbo CVH for a while and I need some in my life, lol! Lee Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted May 8, 2013 Author Share Posted May 8, 2013 Well lads I had a very successful weekend. I managed to seal the fuel leak but the car still wouldn't start. Eventually I traced a bad earth to the EDIS module and she fired in to life! There's still a slight hesitation, but I'm putting that down to the CPS not being long enough (has a 6mm or so gap from the trigger wheel). All in all very happy. Just need to replace the CPS, tape the loom, refit the dash and tighten the running gear. Basically just need time! Lee Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted July 22, 2013 Author Share Posted July 22, 2013 Well, I replaced the CPS last week and she seems much happier now, starts on the button and idles OK. FYI I fitted one labelled for "Fiesta 1.4, 1.6; Granada 2.0;Scorpio 2.0;Sierra 1.6, 2.0" and cut off the screw terminal. Bad new is the gearbox is on its way out so it'll have to come out in favor of the XR3i one until I can get it sorted/upgraded. Just need to put a few things back together and then it's off for a setup. I have a week off again next month so it'll get done then. Lee :top: Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted July 24, 2013 Author Share Posted July 24, 2013 (edited) Managed to upload a few vids of her running too: http://youtu.be/ZyRNIBjqF4M http://youtu.be/RR3LGFFEsCM Lee Edited July 24, 2013 by escortrs2000.co.uk Quote Link to comment Share on other sites More sharing options...
StuDaBear Posted July 24, 2013 Share Posted July 24, 2013 nice work lee, I've had a read through your thread on p/f before. Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted July 24, 2013 Author Share Posted July 24, 2013 Cheers Stu. I put it up here too as there's a lot of people that aren't on PF. For those that aren't, I've done a detailed "How To" on the EFi conversion over on Passionford if you haven't seen it. Lee Quote Link to comment Share on other sites More sharing options...
Admin Ollie Posted July 24, 2013 Admin Share Posted July 24, 2013 hi lee great job you've done there m8 Quote Link to comment Share on other sites More sharing options...
chaz Posted July 25, 2013 Share Posted July 25, 2013 Looks real good mate. Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted September 4, 2013 Author Share Posted September 4, 2013 Cheers lads! Well, as is always the case, the car is never without drama... A month ago I spent a few days on the car. I replaced the gearbox with my old XR3i one and that sorted the whining and crunching for now. During that process I had to fit 2 new track rod ends as they wouldn't come out of the hubs for toffee. But, after a few moves in and out of the garage and up and down the lane the sump gasket gave up Soooo, last week I replaced the sump gasket which cured that issue. FYI I superglued the gasket to the block before putting the sump in, that made the job quite easy. The rubber rocker cover gasket was leaking ever so slightly too so I replaced that with a cork one. Finally the car is 99% ready for an MOT. I'm having a nightmare setting base idle at the moment though so I'm looking for a new OFAC MAP sensor. Once I've replaced that she'll be ready! Cheers, Lee Quote Link to comment Share on other sites More sharing options...
Guest GINGExR2T Posted October 4, 2013 Share Posted October 4, 2013 . Nice project mate, that's my mates Orion, when were the pics taken mate. The Orion is turbo EFi now :-) Ginger . Quote Link to comment Share on other sites More sharing options...
Guest kenny stag Posted October 5, 2013 Share Posted October 5, 2013 Hi Mate , What a cracking job you done. Is it mercury grey,the wiring looked a nightmare. Cheers Kenny Skye Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted October 26, 2013 Author Share Posted October 26, 2013 Hi Mate , What a cracking job you done. Is it mercury grey,the wiring looked a nightmare. Cheers Kenny Skye Cheers Mate, The wiring wasn't too bad, I'm handy with a multimeter, soldering iron and heatshrink which helped. I just wanted to make additions to the '3i EFi loom and I repaired any issues. I've since taped it all up and you wouldn't know it wasn't OEM. Found some more issues the other week, I had to replace the Camshaft oil seal as it was accumulating oil on the lip and I've found a small water leak from one of the pipes on the water pump. The jubilee clip won't tighten any more so I need to replace it with a smaller one. Lee Quote Link to comment Share on other sites More sharing options...
Guest swiftpat Posted November 28, 2013 Share Posted November 28, 2013 Good job pal. Looks mint. Nice orion too. Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted January 7, 2014 Author Share Posted January 7, 2014 An update on recent developments! I think I found the issue setting base idle. Basically the head was warped and had one bent exhaust valve. I tried everything and couldn't sort it. I noticed that it had developed an oil leak from between the head and block so sent it away to be tested. I'm surprised it ran as well as it did! I've now got it back after having a skim, new valve and 4 new exhaust valve seats cut. Just need to fit it and test it. . Nice project mate, that's my mates Orion, when were the pics taken mate. The Orion is turbo EFi now :-) Ginger . Just spotted your comment. The pics were taken at the end of April 2011 just before my brother sold it to Laren. I read on PF that it was EFi turbo now. Me and my bro had some laughs with that Orion! Lee Quote Link to comment Share on other sites More sharing options...
Ian71 Posted January 8, 2014 Share Posted January 8, 2014 Looks nice m8 hope to see it at a show this year Quote Link to comment Share on other sites More sharing options...
Guest GINGExR2T Posted February 8, 2014 Share Posted February 8, 2014 Just spotted your comment. The pics were taken at the end of April 2011 just before my brother sold it to Laren. I read on PF that it was EFi turbo now. Me and my bro had some laughs with that Orion! Lee It's much better with the turbo motor in it, was slow as a snail before :-) :-) just a shame he put Escort Cossie rims on it as they make it drive terrible :-( he defo should have left the Saff wheels on it. Ginger . Quote Link to comment Share on other sites More sharing options...
escortrs2000.co.uk Posted February 12, 2014 Author Share Posted February 12, 2014 I had another day down the garage on the weekend. Managed to get quite a lot done in fairness. I re-fitted the head and it started first time... With no leaks but the bonnet won't close now and it has a puncture I think I've sussed the poor idle too, I blanked off the vacuum hoses that come from the inlet manifold directly below the throttle body (The ones that usually go to the oil breather). Apparently these are needed for the idle??!! Jobs to do: Fit Turbo Cooler Sort Bonnet Latch Sort Puncture Re-fit oil breather MOT Clean and hoover Drive Here are a few more recent pics: Cheers! Lee Quote Link to comment Share on other sites More sharing options...
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