1978 Escort Mk2 RS2000 Cosworth build

1978 Ford Escort Mk2 RS2000

Ford Escort Mk28-page write-up

Mk2 RS2000 Cosworth build — PassionFord

Read the full write-up at Mk2 RS2000 Cosworth build — PassionFord ↗

Photo: Mk2 RS2000 Cosworth build — PassionFord

Shell-up 1978 Escort Mk2 RS2000 rebuilt with a Cosworth 4x4 turbo engine

Owner-builder fostersice bought a stripped 1978 RS2000 shell and rebuilt it from scratch over about a year, fitting a Group 4 style rollcage and chassis mods, a Sierra/Escort Cosworth 4x4 turbo engine and T5 gearbox, custom fuel and exhaust systems, and uprated brakes and suspension. The thread documents the build in detail, including setbacks with leaks and fabrication during first start-up.

Specs

As stated in the original write-up.

Engine: Cosworth 4x4 turbo engine, rebuilt with big-wing sump and baffle plate, modified plenum
Rear axle: Atlas rear axle with 4-link and panhard rod location
Front suspension: World cup crossmember, GAZ gold front coilovers, eccentric adjustable top mounts, adjustable track control arms
Rear suspension: GAZ rear coilovers with powder-coated 5-link bars and poly bushes/rose joints
Front brakes: Hi-Spec 310 x 32mm vented discs with custom bells, Wilwood Supalight 4-pot calipers and Green Stuff fast road pads
Rear brakes: Escort RS Turbo rear discs and calipers
Fuel system: 12g alloy tank, 2lt swirl pot, twin Bosch 044 motorsport pumps and filters, -6 teflon braided lines
Cooling: Custom 60mm core radiator with adjustable side mounting
Pedal box: OBP race pedal box
Interior seats: Sparco Sprint V bucket seats, later Focus RS green Recaro seats ordered
ECU: L1 ECU with Ahmed Bayjoo 330bhp chip and 3 bar map sensor
Paint: 2009 Focus RS Ultimate Green

Parts used

Parts named as used in the original write-up, grouped the way the Parts page groups them. Where one of the shops we index lists the same thing for this car, it is shown underneath with a link to the shop.

Engine 2

Cosworth 4x4 turbo engine
Rebuilt, repainted and fitted as the car's new powerplant
In the shops
Cosworth 4x4 Engine Mount - Road Series ↗Rally Design· £57.38 GBP
Ford Sierra Cosworth/4x4 Brake Hose Kit ↗Rally Design· £111.99 GBP
Ford Sierra Cosworth/4x4 Braided Brake Hose Kit ↗Rally Design· £55.89 GBP
Big-wing sump with baffle plate
Cosworth 2wd sump modified by DB Customs to fit the Mk2 crossmember
In the shops
Mk1/Mk2 RS2000 Escort Alloy Sump Pan With Baffle Plate (RHD) ↗C Bradley Motorsport· £266.90 GBP
Mk1/Mk2 RS2000 Escort Alloy Sump Pan With Baffle Plate (LHD) ↗C Bradley Motorsport· £266.90 GBP
Sump Baffle Kit for X-Flow / Pre X-Flow Front Drop Sump ↗Retroford (Gloucester)· £57.23 GBP

Fuel & Ignition 7

Bosch 044 motorsport fuel pumps
Twin pumps fitted with custom mounts feeding the swirl pot and fuel rail
In the shops
Bosch Injection Fuel Pump 979 ↗West Wales Rally Spares· £217.20
Bosch Type Injection Fuel Pump 909 ↗West Wales Rally Spares· £80.04
Pressure Relief Valve, Lucas Type for Bosch Pumps ↗James Paddock Ltd· £135.00 GBP
Motorsport fuel filters
Fitted in pairs as part of the custom fuel system
In the shops
Malpassi Motorsport V8 Filter King (10mm Tails) ↗Evans & Son Rally Spares· £80.00 GBP
Malpassi Motorsport V8 Filter King (10mm Tails) ↗Evans & Son Rally Spares· £80.00 GBP
Alloy fuel tank with swirl pot
12g alloy tank and 2lt swirl pot fitted with -6 fittings
In the shops
2.8L Injection Fuel Tank with Swirl Pot ↗Evans & Son Rally Spares· £252.00 GBP
2.8L Injection Fuel Tank with Swirl Pot ↗Evans & Son Rally Spares· £252.00 GBP
AH Fabrications Group 4 Escort Mk2 Foam Filled Fuel Injection Tank with Swirl Pot and VDO Boss ↗Motorsport-Tools· £469.00 GBP
L1 ECU with 330bhp chip
Fitted with Ahmed Bayjoo chip, 3 bar map sensor and dark green injectors for the final setup
Turbosmart dual boost controller
Added to control boost late in the build via Eclipse Racing
In the shops
Turbosmart Manual Boost Controller ↗Flyin' Miata· $119.00 USD
Manual Turbo Boost Controller ↗Motorsport Auto (The Z Store)· $109.87
Dual Electric Fan Thermatic Switch Controller ↗Z Car Depot· $89.00 USD
Turbosmart 1200 fuel pressure regulator
Fitted with a new race fuel rail for fuel pressure control
In the shops
Fuel Pressure Regulator ↗Moss Motors – Triumph TR6/TR250· $167.68 USD
Fuel Pressure Regulator - XJ ↗Angloparts· €178.50 EUR
Bosch Fuel Pressure Regulator ↗Retroford (Gloucester)· £73.17 GBP
Pipercross race foam air filter
Fitted to the turbo intake to suit the power target and available space
In the shops
Pipercross C602D Performance Air Filter ↗West Wales Rally Spares· £86.08
Pipercross C3003 Performance Air Filter ↗West Wales Rally Spares· £45.34
Pipercross C3001 Performance Air Filter ↗West Wales Rally Spares· £45.34

Cooling 2

RS500 intercooler
Fitted with a cut front panel for more airflow
Custom 60mm core radiator
Made with adjustable side mounting and fitted with custom hoses
In the shops
2-Core Aluminium Radiator - Mini ↗MGOC Spares· £108.10
Alloy 2-Core Radiator (All Minis) ↗bpnorthwest.com· $356.26 USD
3-Core Radiator (Mini up to 1992) ↗bpnorthwest.com· $209.89 USD

Gearbox & Drivetrain 1

Hydraulic clutch kit
Fitted to the T5 gearbox to convert from cable operation
In the shops
Escort Mk1 & Mk2 Hydraulic Clutch Pedalbox Fitting Kit ↗Gartrac· $218.00 USD
Escort Mk1 & Mk2 Hydraulic Clutch Pedalbox Master Cylinder Kit ↗Gartrac· $509.00 USD
Centre Push Hydraulic Clutch Shim/Spacer (19mm) ↗Evans & Son Rally Spares· £25.45 GBP

Suspension & Steering 4

World cup crossmember
Fitted as part of the front suspension and to accept the Cosworth driveline
In the shops
World Cup Crossmember ↗Retroford (Gloucester)· £0.00 GBP
World Cup X-Member Crossmember ↗Evans & Son Rally Spares· £241.00 GBP
World Cup X-Member Crossmember ↗Evans & Son Rally Spares· £241.00 GBP
GAZ gold front coilovers with eccentric top mounts
Fitted to the front suspension
In the shops
Alloy Eccentric Top Mount (105mm Large Hole) ↗West Wales Rally Spares· £94.62
Escort MK1/2 Small Top Steel Eccentric Top Mount ↗Rally Design· £33.50 GBP
Escort MK1/2 Small Top Aluminium Eccentric Top Mount ↗Rally Design· £41.00 GBP
GAZ rear coilovers
Ordered and fitted to rear suspension along with powder coated 5-link bars
In the shops
Gaz Rear Coilover Damper (Short Type) - Ford Escort Mk1/Mk2 ↗Burton Power· £131.50 GBP
Adjustable track control arms
Built and fitted with rose joints and yellow poly bushes
In the shops
Track Control Arm ↗James Paddock Ltd· £73.00 GBP
Track Control Arm Bush ↗James Paddock Ltd· £6.25 GBP
Track Control Arm Securing Bolt ↗James Paddock Ltd· £1.25 GBP

Brakes 4

Hi-Spec 310 x 32mm vented front discs and custom bells
Fitted to the front brake setup
In the shops
Vented Brake Discs 240x24mm for XR3i Caliper (Pair) ↗C Bradley Motorsport· £115.50 GBP
Brake Disc, vented, front ↗Moss Europe (UK)· £38.50 GBP
Front Vented Brake Disc 326mm ↗British Auto USA· $81.12 USD
Wilwood Supalight 4-pot calipers
Fitted at the front with custom mounts and Green Stuff pads
In the shops
Uprated Wilwood Brake Kit with 4-Pot Calipers and Vented Discs ↗Robsport International· £ 732.00
Uprated Wilwood Brake Kit (Lightspeed 4-Pot Calipers, Vented Discs) ↗Robsport International· £ 732.00
X-Drilled & Grooved Vented 260x20 Brake Disc For Wilwood 4 Pot Caliper ↗C Bradley Motorsport· £74.90 GBP
Escort RS Turbo rear discs and calipers
Fitted to the rear brake conversion
In the shops
Vented Brake Discs 240x24mm for XR3i Caliper (Pair) ↗C Bradley Motorsport· £115.50 GBP
M16 Ford Escort/Capri Replacement Caliper (Vented Disc) ↗Rally Design· £54.25 GBP
Escort MK1/2 Front M16 Brake Calipers for Vented Disks (Pair) ↗Evans & Son Rally Spares· £159.09 GBP
Braided brake lines
Custom made front, rear and handbrake lines fitted to replace standard pipework
In the shops
Stainless Steel Braided Brake Lines ↗Moss Motors – Triumph TR6/TR250· $115.75 USD
Braided Stainless Brake Line Kit (NC chassis) ↗Flyin' Miata· $129.00 USD
Braided Stainless Steel Brake Line Kit (ND/Fiat) ↗Flyin' Miata· $119.00 USD

Wheels & Tyres 1

4-to-5 stud hub conversion
Front and rear hubs converted to take 5-stud wheels
In the shops
Escort Mk1 & Mk2 Group 4 Rear Wheel Hub Kit, Fully Floating (Metric Studs) ↗Gartrac· $631.00 USD
ARP Wheel Stud for Good Parts Rear Hub ↗Good Parts· $7.00 USD
Stud Kit, Rear Hub Attachment, Heavy Duty ↗Good Parts· $39.00 USD

Body & Trim 1

Group 4 rollcage
Fitted along with strut brace and tank base as part of the shell preparation

Interior 3

Sparco Sprint V bucket seats
Fitted as the car's seats
In the shops
Sparco Sprint Race Suit (Black) ↗West Wales Rally Spares
OBP race pedal box
Floor mounted pedal box fitted with the throttle cable
In the shops
Mk2 Escort O/E Hydraulic Pedal Box ↗C Bradley Motorsport· £322.80 GBP
Escort MK2 Hydraulic Clutch Balance Bar Pedal Box ↗Rally Design· £225.00 GBP
Clutch Lever Clevis Bracket For Hydraulic Pedal Box ↗C Bradley Motorsport· £5.90 GBP
Carbon-look door cards
Fitted to the interior trim
In the shops
Escort Mk2 Carbon Fibre Look Door Cards (Full Set) ↗Evans & Son Rally Spares· £154.54 GBP
Escort Mk2 Rear Carbon Fibre Look Door Cards (Pair) ↗Evans & Son Rally Spares· £80.00 GBP
Escort Mk2 Front Carbon Fibre Look Door Cards (Pair) ↗Evans & Son Rally Spares· £83.63 GBP

Electrical 1

iPhone-based digital dash
Used with a speedo/data logger app in place of a conventional dash display

Photos

400 pictures collected from the write-up, in the order they were posted, shown from Mk2 RS2000 Cosworth build — PassionFord. A picture opens larger here, with the way through to the page it is on.

fostersice · Apr 5, 2009 | 08:50 AM 14this post at Mk2 RS2000 Cosworth build — PassionFord ↗

Photo: Mk2 RS2000 Cosworth build — PassionFord

fostersice · Apr 5, 2009 | 08:53 AM 2this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Apr 10, 2009 | 08:34 AM 2this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Apr 10, 2009 | 08:39 AM 1this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Apr 10, 2009 | 03:10 PM 1this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Apr 28, 2009 | 11:59 PM 12this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 3, 2009 | 08:53 AM 7this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 24, 2009 | 06:15 AM 6this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 24, 2009 | 06:16 AM 13this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 24, 2009 | 06:18 AM 7this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 24, 2009 | 06:18 AM 2this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 24, 2009 | 06:20 AM 7this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 24, 2009 | 06:21 AM 5this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 26, 2009 | 10:40 PM 3this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 27, 2009 | 09:25 PM 2this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 28, 2009 | 10:46 PM 1this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 29, 2009 | 10:57 PM 11this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 30, 2009 | 09:25 PM 4this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · May 31, 2009 | 10:51 PM 8this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jun 20, 2009 | 09:04 PM 19this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jul 1, 2009 | 04:15 PM 12this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jul 3, 2009 | 06:16 PM 15this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jul 7, 2009 | 08:12 PM 14this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jul 16, 2009 | 09:27 PM 15this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jul 26, 2009 | 02:11 PM 5this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jul 26, 2009 | 02:14 PM 5this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jul 26, 2009 | 02:21 PM 3this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jul 26, 2009 | 02:41 PM 8this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Aug 7, 2009 | 06:37 PM 10this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Aug 7, 2009 | 06:39 PM 2this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Sep 20, 2009 | 08:21 AM 30this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Oct 27, 2009 | 10:02 PM 17this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Nov 1, 2009 | 01:30 AM 14this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Nov 1, 2009 | 01:35 AM 13this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Nov 22, 2009 | 12:30 PM 5this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Dec 5, 2009 | 07:39 PM 3this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Dec 5, 2009 | 07:42 PM 1this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Dec 5, 2009 | 07:45 PM 1this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Dec 18, 2009 | 07:12 PM 3this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Dec 29, 2009 | 05:35 PM 13this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Dec 30, 2009 | 04:56 PM 17this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Dec 31, 2009 | 05:47 PM 29this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jan 1, 2010 | 09:11 PM 3this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jan 1, 2010 | 09:14 PM 1this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jan 1, 2010 | 09:17 PM 1this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jan 6, 2010 | 07:16 PM 2this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jan 13, 2010 | 01:08 AM 4this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jan 15, 2010 | 04:11 PM 9this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jan 17, 2010 | 03:55 PM 2this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jan 17, 2010 | 09:10 PM 12this post at Mk2 RS2000 Cosworth build — PassionFord ↗

fostersice · Jan 22, 2010 | 03:53 PM 4this post at Mk2 RS2000 Cosworth build — PassionFord ↗

How it was done

Starting condition

The builder bought a 1978 RS2000 shell on eBay that had been stripped down over 18 years by the previous owner, listed with a world cup crossmember, Atlas axle, 4-link, panhard rod, X-pack, quick rack, roller top mounts and Bissell shocks fitted, but no engine or gearbox.

Chassis and rollcage work

On inspection the 4-link boxes and rear turrets were found fitted incorrectly, too low and at the wrong angle for rear seats. New boxes, turrets and mounts were ordered and the shell went for a Group 4 rollcage, large gearbox and diff tunnels, a strut brace and bulkhead modification to accept a Cosworth engine.

Suspension and brakes

GAZ coilovers front and rear were fitted along with adjustable track control arms, eccentric top mounts and 4-to-5 stud hub conversions. Later in the build Hi-Spec discs with Wilwood 4-pot calipers were fitted at the front and Escort RS Turbo brakes at the rear, with custom braided brake lines.

Paint and bodywork

The shell and interior were painted in 2009 Focus RS Ultimate Green after the car had door bars and a dash bar fitted. The boot floor was cut and reshaped to fit a twin exhaust exit, and various body modifications accommodated the Cosworth driveline.

Engine and driveline

A Cosworth 4x4 turbo engine was stripped, cleaned, repainted and bench tested before fitting, with a modified 2wd sump widened for the Mk2 crossmember, an RS500-style intercooler, a rebuilt T5 gearbox and a custom 3-inch exhaust system built around twin rear boxes.

Fuel, cooling and electrics

A custom fuel system with an alloy tank, swirl pot, twin 044 pumps and braided lines was built, along with a custom radiator and hoses. Wiring was largely redone, including fuel pump and lighting circuits, with an iPhone used as a digital dash and data logger.

First start and setup

On first attempted start-up the car suffered a diff seal leak, water pump weeping, a fuel pump leak that flooded the boot, and brake and clutch line leaks, each traced and fixed in turn. A turbosmart boost controller, race fuel rail and regulator, and a Pipercross filter were later added, with the car booked in for a dyno session.

A summary in our own words. The full account, with all its detail, is in the original write-up: read it at Mk2 RS2000 Cosworth build — PassionFord ↗

Worth knowing

Fit braking and fuel system components correctly the first time since they are the most important parts of the build
A stripped shell described as having work done can still need chassis mounts and turrets redone before a rollcage can be fitted
New parts can still fail or leak, so test fitted components such as fuel pumps before relying on them