-
FAST ROADANGLIA STCOSWORTHV6 CAPRI
THAMES 400EV8 CAMPER!
Top buying advice inside
BUY IT:
FIESTARS1800
ENGINE SWAP
Make those fibreglass parts look like metal!
CHROMEPLASTICS
HOW TO:
Your favourite ever transplants revealed
ENGINESWAPS
TOP 10:
400bhpMk2EscortV8for theroad!
22A
SEE INSIDE
VOTEFOR YOU
R
CLASSICFORD
OF THEYEAR
Seep22
CORTINA 2.0S MK4RARE AND ORIGINAL
Tips and tricks, pro advice, and awesome feature cars to inspire
your next transplant!
PLUS: AXLE STANDS TESTED + MK1 ORION AND MK1 ESCORT PROJECT
IDEAS + CARS & PARTS FOR SALE + TECH PROBLEMS SOLVED + TUNING
RECIPES
16-VALVE ESCORT
Hybrid Heroes!SPECIAL
-
Out and about with our band of Blue Oval-loving writers and
photographers.
THIS MONTH
RJAMIE
Serial Ford owner,Steve OzzyOsbornes latestproject is a
ST170powered Anglia.Jon shot it (andOzzy) for this issue.
Closet GM fan Jamie views the XE in Paul Reenes Mk1 track terror
as making perfect sense. We might just agree with him. Page 92.
JON
STAFF WRITE
How much does Marc want Mitch Hughes rare and untouched Mk4
Cortina 2.0S? Quite a lot. Find out why starting on page 60.
MARC
CONTRIBUTOR
NTRIBUTOR
How To Contact Us
Write to: Classic Ford, Kelsey Media, Cudham Tithe Barn, Berrys
Hill, Cudham TN16 3AG, UKTelephone: 01225 687699 Email:
[email protected]
ngine swaps havedays of the 60s, winto Anglias ever
nearly 50 years on, a claquad-cam, all-alloy V8to make it more
practic
Bigger engines in smof course Doc MerFalcon V8-powered M60s, but
the differenceconversions and the hocunning involved. Wevgreat
examples of this irelative ease of a Coswoa Capri (page 46) to
thLS1 in Finlays MacPh26), which was more owithin the realms of a
tCheck them out, thenyour tape measure and
.
E e come on a long way since the headywhen 1500 Pre-Crossows
were ttedy weekend. I mean, whod have thoughtassic Ford enthusiast
would be tting ainto his Thames camper (see page 8)
cal for todays roads?all Fords are nothing new,
eld famously raced aMk1 Cortina in the late
e now is the quality of theome-brewed engineeringve
cherry-picked a fewin this issue, from theorth 24-valve swap
into
he slightly insane 400 hpersons Mk2 Escort (pagef a challenge to
t, but still
typical classic Ford nut.get down the garage with start
plotting.
-
46
ON THE COVER
ON THE COVER
ON THECOVER
98 THE ESCORT RS TURBOSTORYCan you beleive its 30 years since
themighty RS Turbvo was first revealed tothe public? Graham Robson
recountsdhow the car came about, and how itchanged fast Fords
forever.
104
10898
6 December 2014
8
26
32
84
36ON THE COVER
ON THE COVER
104 OLD SKOOL FORD DRAG CHALLENGE All the action from the final
round of the popular quarter-mile series.
108 RAC RALLY CHAMPIONSHIP Escorts and Cortinas battle for stage
glory on the Trackrod Historic Cup.
8 GRAFTERS: Thames 400EAs if restoring a rare Dormobile
wasntchallenging enough, this vans goingV8.
26 400BHPMK2ESCORTV8Because too much is not enough.
32 TOP10:Transplant EnginesYou voted, we counted, heres the
result.
36 HOMEBUILT HERO:Anglia 105EBase-model Anglebox gets
modern16-valver and matching running gear.
46 COSWORTHCAPRI V6Classic 90s styling and a 24-valver.
54 CLUBMEET:GloucesterOld Ford ClubPopular south west meet
celebrates its10th anniversary.
70 HERITAGE: Cortina 2.0S Rare Mk4 saved and recommissioned.
Features
54
SUBSCRIBE!SEE PAGE
12Contents
-
116 BUYING GUIDE: Fiesta RS1800Getting rarer and more
collectible by the day, whatyou need to know if youre buying a
Fiesta RS.
ON THECOVER
5 TERDSEEPAGE14
ON THECOVER
December 2014 7
December 2014Regulars
Classic Ford Tech
78
88
43 FAST ROAD BUILDS Five specialists reveal what car and engine
combo theyd build for the road.
52 ESSENTIAL SWAP INFO What you need to do, and why.78 HOW TO:
Chrome plastic Step-by-step guide to making those glassfibre parts
look like the real thing.
84 OUR PROJECTS Updates on Robs Zetec Capri project.86 EXPERT
CLINIC 88 ON TEST: Axle stands Seven sets put through thier paces.
128 PROJECT HUNTER
The cars you should buy and modify.
74 NEXTISSUE124 READERCLASSIFIEDS:
Cars and parts for sale and wanted.
14 NEWS: Classic Ford Show 2015 date revealed, no more tax
discs, plus Rusty Cornerand Image Of The Month.
66 WHATS ON72 MAILBOX
Your letters, emails and comments.
18 PRODUCTS: The best new parts and goodies for your classic
Ford projects.
128
ON THE COVER
92 MK1 ESCORT TRACK CAR The search for the ultimate track toy
led Paul Reene to create this brutal XE-powered with all the
trimmings.
128
p18
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8 December 2014
THIS IS KEVS FIRST FULL-ON RESTORATION, AND HE TOOK THE CAMPER
ON BECAUSE HE
SPOTTED IT FOR SALE AND FELT SORRY FOR IT...
Van:1959Thames400EDormobile camperStart condition:Rusty,
non-runninganddilapidatedCondition now:Major bodyworkcompleted,
engine install trail tted,brakes and suspensionupgradedTime taken
so far:Four year,on-and-off asmoneyand life allowsEstimated date of
completion:Noxeddeadline
-
Name:Kevin BarlasAge: 29Job: Metal FabricatorLocation:
Edinburgh
eve come across some incredible projects over the years, but
this one, although
its still a while from completion, is already legendary. Why?
Because not only did Kevin Barlas from Edinburgh take on a rusty
Thames 400E camper van that had been sat in a eld for years one of
the most complicated vehicles we know of to restore but then he
decided it would be a good idea to replace the original Consul
plodder engine with the quad-cam V8 and autobox from his daily
runabout Lexus... as you do!
When (and if) youve got your head round that, then start to
consider the massive amount of work involved in upgrades to the
rest of the running gear for such a plan, plus the bespoke
fabrication needed to make it all t and Kevs project becomes a bit
of a brain-melter. Oh, and just a couple of extra pieces of
information to really lower the jaw to the oor... this is Kevs rst
full-on restoration, and he took it on because he spotted the
camper on a forum post and felt sorry for it. Like we already said
legend... or mad. Yes, with hindsight maybe its down to
madness.
THEY CALLYour projects: By rights this 400E should have been
scrapped, but that
hasnt stopped Kev Barlas from taking it on oh, and dropping in a
V8...Words Marc Stretton
Photos Adrian Brannan
IT MADNESS
December 2014 9
W
your projects: thames 400eHeroes!
HybridHybrid
S P E C I A L
ENGINE SWAP
-
Kev has fabricated a new cradle to hold the massive auto box he
plans to shift gears using the original column shift.
Howdidthiscrazyprojectcomeabout?I had a Mk2 Consul, which Id
stumbled across while on the hunt for my dads old Morris Minor, so
had become a member of the Pre-1967 Ford Owners Club. One day a
forum post popped up with details of the camper and that it was for
sale. It looked sad and in need of rescue, so I bought it, and it
came pretty cheap too, which helps.
Is this really your rst restoration?Yes. Id put sills on the
Consul, but that was about it for car restoration. Ten years
working for a blacksmith and then several metalwork fabricators
means I wasnt too scared of cracking on with it though.
Was the bodywork very bad?Some of the major sections, including
the chassis and front panel were actually very good. But the roof
could be lifted off in places and its gutters were terrible. These
are very
10 Deember 2014
WITH NO REPAIR SECTIONS AVAILABLE, EVERYTHING HAS HAD TO BE
RECREATED
Kevs playing the long game with this project: hes wisely not set
a deadline to nish it.
Braking now courtesy of Mk2 Transit discs and callipers.
Original front panel has been saved.Capri donated its axle.
-
complicatedtoxand Ihadsomesectionsmadeup,which I let in, insmall
lengthsatatime.All aroundtheedgesat thebottom,especially
thedoorsteps,wasbadtoo.Andwithnorepairpanelsavailableeverythinghasbeenrecreated,sometimesusing
justtheremnantsof theoriginalsteelasapattern.All very
time-consuming.
Wheredoyoudothework?I sharea largeworkshopwitha
friend,sohaveplentyofspaceandearlyon
Idesignedandttedadodecahedron-shapedrolloverframetoturn
thevanforaccessthrough360-degrees.Thathelpeda lot. I
alsomadeahome-mademetal folderwhichhasbeenusedextensively
formakinguppanelsandrepairsections.
Werethecamper
interiorandroofsalvageable?Thepop-uproofwillneedsomestitchingbutissaveable,but
the interiorwasscrap.Working in thesalvage industry, I shouldbeable
tondsomeperiod-styleseats,bedsandcupboardsandcamperaccessorieswhenthetimecomes.
Whatotherupgradeshaveyoudone?Thebrakesandsuspensionobviouslyneedupgrading,andthereshadtobea
lotoffabricationandengineeringwork to improvethings.Thesuspension
isall
refreshedwithSpaxdampersandthefrontbrakesarenowTransitMk2venteddiscsandfour-potcallipersonmodiedThameshubs.Therearaxle
isaCapriSalisburyone,as it is thesamewidthasthevansoriginal.
Whatwill theoverallstylebe?Iwant it to lookstandard,so
Icanpullup totheboyracersat the lightsand
leavethemstanding,notknowingwhat
justhappened.So,aperiodpaintshadeandbandedsteelstheoriginal15
inchonestOKover thebiggerbrakes.
Yousaytheresnocompletiondate
inmind.Whynot?Becausetheresnorush,and Idontwant
tocompromiseonthequalityofworkbytryingtowork toadeadline.Plus
forevery job Icanthinkneedsdoingtherewillbe10that Ihavent
thoughtof.Therewillbeabitofabreaksoontoo,as Imaybe
losingmyworkshop,buthavespacetobuildabiggarageathome.Theprojectgetsnishedwhen
itgetsnished.
Doestheextentoftheworknotoverwhelmyou?Itwouldmostpeople.No,but
itprobablywould if I lookedat thevanasawhole.Right fromthestart
Ihavelookedonthecamperasaseriesof tasksand Imakesure Inishone
jobbeforestarting thenext. I like to thinkanything
ispossible,soknowIcannish...oneday!
Anyoneyoud
liketothank?Yes,mydadJohnandbrotherRossforalltheirhelp,plusmyverysupportivewifeJanka,whohaseven
joined inatsometimes.Also Ihavehadmassivehelp fromSandyGlenof
theFord400EOwnersClub(www.thames400e.freeserve.co.uk),withtipsandadvice,andalsomaterials,
toolsandequipmentborrowingfromworkwww.holyroodarchitecturalsalvage.com.
Foramuch-more in-depth
lookatthisawesomeproject,Kevhasdetailedhisworkoverthepast
fouryearsonthePre-1967FordOwnersClubforum...Wellworthacheckout,butgiveyourselfa
fewhours togothroughthe19-page(andcounting)
thread:www.pre67Ford.hyperboards.com
FIT IT:LEXUS V8 INTO THAMES 400E
Fortunately, the starting point is that the engine block ts
between the original chassis rails and I used some custom mounts
with BMW rubbers, says Kev. To get it to physically t a lot of
original engine bay and seat-base metalwork has to disappear, and
then be reconstructed on a bigger scale. The sump is modied to
clear a steering arm, theres a fabricated gearbox cradle and Ive
had to reposition the throttle body, but apart from that it all
goes pretty easily, with custom exhausts on the list to be made up
later. Using the auto box I should be able to retain the
column-change lever, too!
December 2014 11
your projects: thames 400e
V8 inside: the Thames will be a proper sleeper when its
nished.
Kev had to reposition the V8s throttle body.
Now it sits neatly under the engine cover.
Most of the bottom half of the van was rotten. Panels are thin
on trhe ground so Kev has had to make up his own.
The van was bad when Kev rst got it. Very bad.
New engine neatly ts between the chassis rails. The steel wheels
are staying though they will be widened.
Heroes!
HybridHybrid
S P E C I A L
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14 December 2014
he Classic Ford Show Europes largest classic Ford event will
take place on Sunday, May 31, 2015, once again at the
world-famous
Santa Pod Raceway.If you love your classic Fords you will love
what this
show has to offer. There will be all-day strip action, Ford-only
run-what-yer-brung, breathtaking stunts from the best in the
business, thousands of club cars on display and we havent even
touched on all the feature areas at the show! So start working on
those project cars now and put this date on the 2015 calendar!
T
TAX DISCS ABOLISHEDNo need to display the disc on your classic
Fords screen.From last month, drivers in the UK no longer have to
display a paper tax disc on a vehicle windscreen. You will still
need to pay vehicle tax and the Driver and Vehicle Licensing Agency
(DVLA) will hold a digital record.
To drive or keep a vehicle on the road you still need to pay
vehicle tax and you will still get a renewal reminder when your
vehicle tax is due to expire. This applies to all types of vehicles
including those that are exempt from payment of vehicle tax.
If you have any remaining months left on your current paper tax
disc from October 1, 2014, you can either remove the tax disc from
your vehicle or display the disc until it expires.
From now on, when buying a vehicle, the vehicle tax will no
longer be transferred with it:
You will need to get your new vehicle taxed before you can use
it, or alternatively, tax your car at a Post Ofce branch that deals
with vehicle tax.
If you sell a vehicle and have notied DVLA, you will
automatically get a refund for any full calendar months left on the
vehicle tax.
You will no longer need to make a separate application for a
refund of vehicle tax. The DVLA will automatically issue a refund
when a notication is received from the person named on DVLA vehicle
register
that:s4HEVEHICLEHASBEENSOLDORTRANSFERREDs4HEVEHICLEHASBEENSCRAPPEDATAN
Automated TreatmentFacility.s4HEVEHICLEHASBEENEXPORTED
s4HEVEHICLEHASBEENSTOLENs4HEVEHICLEHASBEENREMOVEDFROMTHE
road and the person on the vehicle register has made a Statutory
Off Road Notication (SORN).s4HEPERSONONTHEVEHICLEREGISTERHAS
changed the tax class on the vehicle to an exempt duty tax
class.
The Classic Ford Show is just seven months away!
Europes best show cars will be attending.
31.05.2015
The classic Ford-only drag strip is open all day.
All Classic Ford Show tickets will be initially going on sale in
January 2015. You may think thats a long way away, but it pays to
be quick literally! as there will be special Early Bird offers for
those who plan ahead.
Dont miss out on all of the latest news and the Early Bird
ticket offers by signing up to the Classic Ford Show newsletter. Go
to www.classicfordshow.co.uk and follow the link.
TICKETS ON SALE JANUARY
Expect surprises at The Great Unveiling. Shades and 50s shirts
optional.
Say goodbye to the little round disc.
-
classic ford news
FLYING HIGHYou cant beat a bit of closed-road rallying for
capturing Escorts mid-ight. Heres Rob Smith and Alun Cook on their
way to second overall in the International event and rst in the
Historic class on the Manx Rally in their RSR BDG-powered Escort.
Photo Mark Writtle Photographic
Terminally-rotten old Fords. Even on holiday theres no escaping
the lure of a potential classic Ford project. Just ask Pat Burns
who spotted this two-door Mk3 Cortina on a building site near Mesao
Frio in Portugal while on his holibobs recently. The builders were
a little bemused by my interest in the car, reckons Pat, though Ive
no idea what the other lash-up of a car was keeping it company.
Spotted an unloved Ford? Email photos and details to:
[email protected].
Over the past few years, ethanol has struck fear into the hearts
of many classic Ford owners. British Motor Heritage (BMH) can now
offer a solution - the supply of ethanol-free fuel. The company is
now offering both unleaded and leaded ethanol-free petrol, courtesy
of the American supplier VP Racing Fuels. It is being sold in drums
of 5 or 54 US gallons (18.93 or 204.41 litres).
Both these ethanol-free fuels have a shelf life of up to two
years and provide extra protection against detonation.
Thecostofan18.93 litredrumis67.50,whichequatestoapriceof3.57per
li dutyandVAT),plusdeliver nt.www.bm
ETHANOL-FREE FUEL LAUNCHEDClassic-friendly juice on offer.
Not voted for your Classic Ford Of The Year yet? Then hurry, as
voting closes on November 14!
There are 12 stunning classic Fords to choose from all featured
in the magazine over the last year and you can vote for your
favourite either by text or on our website at
www.classicfordmag.co.uk.
Turn to page 24 to see all of the 12 nominations, and to nd the
full details of how you can place your vote.
Well reveal the winner in the January 2015 edition, on sale
December 5, 2014.
IMAGE OF THE MONTH
FOR YOUR FAVOURITE
CAR OF THE YEAR
A
D
GJ
Weve seen some great feature cars in 2014,
now its up to you to select your favourite!
A. Anglia 105EOwner Steve MossFeatured Decembeer 2013Bu lt from
sc atch by Steve hsdad and frends this bespokerace car is a work of
art that unsa top spec XE engne Aguaranteed head turnerB. Fiesta
XR2ner Sean Chessumtured December 2013the stars of last yearsnve
ling Seanswed Yamaha engnedis a feat of cleverthat rea ly looks
the
a 3.0Sd2014hingly
1 sitsds tosex
running a 2 l tre Zetec on bikecarbs Robs homebu lt 300Egives
new meaning to the termrapd del very
F. Capri 3.0SOwner Wayne ChampionFeatured May 2014If you
descrbed your dream-spec Mk3 Capri the chances are Waynes hrot le
bodied, Cossie 24 valver drppng wth Series X goodes would be it
Stunning.G. Escort RS2100
Owner Steve CroppFeatured Summer 2014Pa t of our Class Of 2014
lne-up, this Escort has t a l with ad fferent take on the RS2000
livery and exquisite a tenton to detail One of our favou ite Mk1
Escorts of recent yearsH. Anglia 105EOwner Tom CroppFeatured July
2014Lke father like son Tomscreated ths unque arched 105E
bu lt to roam the road and stripthanks to a top spec C
ossflowFast and showstoppngI. Thames 400Ewner Malcolm Midgleytured
Summer 2014ously d ff cu t to restoreeless Malcolm went theturnng
ths once rottento a rare and che ishedords early 60slassc
J. Mk1 Cortina GTOwner Tony Bar owFeatured January 2014Drppng wi
h perod 60s cool (and parts), Tonys Alan Mann Racing-liveried Mk1
looks the part and and sounds it, too, thanks to a Throbnozzle
Racing Pre-Crossflow.
K. Mk1 Fiesta Owner: Christian PikeFeatured: Summer 2014Inspired
by the awesome 1979 Monte Carlo-spec works Fiestas, Christians
built this cracking tribute, only with more-modern running gear and
even better looks.
L. Mk1 Capri Owner: Dave MagenisFeatured: August 2014Restored
not once, but twice by Dave, this Mk1 has all the right ingredients
for a classic early Capri with a fruity Pinto, uprated running gear
and drop-dead gorgeous body and paintwork.
HOW TO VOTEChoose the car you want to vote for from the
selection above, then head online to our website at:
www.classicfordmag.co.uk
and follow the instructions. Voting closes November 14,
2014.The winning car will be revealed in the January 2015 issue,
on sale December 5.
FOR YOUR FAVOURITE
2014
CAR OF THEYEARB
C
E
F
H
IK
L
CLF218.vote.indd 23
s where rele n,
tte
Mk3 looks like an abandoned resto.
-
FRONTEND
Established way back in 1982, the Mk1 club has long had an
enviable reputation for its spares programme actively
remanufacturing many items to help keep these 60s classics on the
road. But the club is much more than a spares outlet, with a busy,
bi-monthly magazine, decent tech advice, regular pub meets and the
annual Cortina Rally which attracts enthusiasts from all over
Europe.
Membership costs 30 per year for UK enthusiasts, and you can nd
out more and join up at www.mk1cortina.com.
CLUB PLUGMk1 Cortina Owners Club
The Mk1 club welcomes standard, modied and competition cars.
BE SURE TO RATE &
REVIEW US +++++
GET IT ON THE MOVEDownload the digital edition
today!http://bit.ly/classicford
Whats inside the January issue! Here are three reasons not to
miss the next issue:1. Included with all print editions will be a
cracking 2015 poster calendar to keep you entertained all year.2.
Well be announcing the Classic Ford Of The Year along with a whole
host of trophies in our special Classic Ford Awards feature.3. Were
having a sleepers and street racers themed issue, so expect many ne
Fords built to win the trafc light grand prix.
The January 2015 issue hits the shelves and is available to
download from Friday, December 5, 2014. Why not subscribe to make
sure you dont miss it? Check out our latest offers on page 12.
COMING UP
LancasterInsuranceClassicMotorShowWhen:November14-16Where:NEC,BirminghamB401NT,UK
Where to go this month
Whats going on: The last place you want to be, is an outdoor car
show in the UK in November, which is why the Lancaster Insurance
Classic Motor Show, held rmly indoors at the NEC for many years, is
the perfect place to be this month. Tens of thousands of classic
car enthusiasts converge on the halls for a long weekend of
old-school celebration. Blue Ovals always play a big part thanks to
the efforts of the classic Ford clubs, with top displays spanning
the entire old Ford spectrum, plus the Meguiars Club Showcase
Finalists features a stunning Escort RS1600 and Cortina 1600E in
its line-up. Check out the cars, buy spares, tools and consumables
or even watch Mike Brewer and Edd China from Wheeler Dealers.Find
out more: www.necclassicmotorshow.com
Is this Cossie-powered Fiesta van the ultimate street
sleeper?
Expect only the nest classic Fords on display at this months
Classic Motor Show at the NEC.
-
18 December 2014
BEADING MARVELLOUS WAX34.99 Valet Pro
Theres no shortage of automotive waxes on the market at the
moment, but this latest formula from Valet Pro called Beading
Marvellous offers 3-6
months of high gloss protection, all while acting as an
effective barrier to road grime. Valet Pro reckon its paste
consistency makes it easy to apply by hand or machine, and they say
it needs just 5 minutes to cure before it can be buffed off.
Impressive.Contact: 01892 277001www.valetpro.co.uk
WE THE TERRORS T-SHIRTSFrom 16 We The Terrors
We The Terrors have just released a new range of cool T-shirts.
The latest designs include these Mk2 Escort Mind the Gap, and RS200
Beast of Boreham T-shirts, along with many more great graphics.
Various colours available, in sizes ranging from small to XL. Check
out their website for full details.Contact:
www.wetheterrors.bigcartel.com
ESCORT FRONT CHASSIS RAILS
TBC MagnumMagnum Car Panels are on a roll right now. The latest
goodies to arrive from them are these engine bay chassis rails for
the Mk1 Escort. Both right and left-hand sides are available and
they come with the crossmember captive mounting nuts as per
original.Contact: 01706 359666www.magnumclassicfordpanels.co.uk
COSWORTH YB DISTRIBUTOR SENSOR
50 WebconWebcon have just released a genuine Weber-
Marelli replacement distributor pick-up sensor for thCosworth YB
range of engines. Suitable for both 2wd a
4wd units the sensor is available now from Weber dealefor just
50.Contact: 01932 787100www.webcon.co.uk
C
-
classic ford gear
1150 eIf youre building the ultimatespec Anglia then take a look
atwhat Ray Gimberts just hadproduced. These beautifully-produced
doors feature both carbon bre outer skins and frames and weigh just
2.8 kg each with the standard Anglia weighing 15.5 kg, that makes
them over ve times lighter! Not cheap, but then the ultimate never
is.Contact: 07785 278445
ULTIMATE QUIK INTERIOR DETAILER12.99 Meguiars
Ultimate Quik Interior Detailer is an interior cleaner that
safely cleans all those areas in your classic Ford that you come
into contact with everyday such as steering wheels, stereo, dash,
door panels and centre consoles.The deep cleaning formula dries
fast and leaves behind a clean,
n shine that Meguiars or weeks.
2416696rs.co.uk
SPEEDO CABLESFrom 13 Burton Power
When owning and maintaining a classic Ford, its often the
smaller parts that get overlooked. Things like a dodgy, inaccurate,
or non-existent speedo can really dampen the driving experience.
But thanks to Burton Power its now easily xed, with new speedo
cables available for most Ford gearboxes (including the Cosworth
range) and with prices starting at less than 13.Contact:
www.burtonpower.com
OOK VERS
9.99 Richbrooker around the corner you lot worse than invest in
one
car covers from Richbrook. e includes a large variety of
Ford models, and they can be d with Blue Oval badging. The
feature besp[oke door mirror
ts, elasticated hems and a chable strap for easy tment. The
thable fabric allows damp and
densation to evaporate, and the ecial bonded coating means that
95 r cent of standing water runs off.
They even fold down for simple storage, easily tucked into the
special bag provided.Contact: 01328 862387www.richbrook.co.uk
CLASSIC FORD SUBSCRIPTIONFrom 20 My Favourite Magazines
Stuck for what to buy your classic Ford-loving better half for
Christmas? Afraid the in-laws will buy you yet another useless
ornament for the garden you never go in? Then may we recommend a
gift subscription to the worlds biggest and best-selling classic
Ford magazine! Delivered straight to yours or your loved-ones door
for the next 12 months, you get 13 issues of old Ford goodness,
typically saving 20 per cent off the cover price. Its not just
conned to the UK, too; your favourite Ford magazine can be
delivered all over the world, in print or digital form.Contact:
0844 8482852 (international +44 1604
251045)www.myfavouritemagazines.co.uk
FLIA DOORS
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IC RCARFrom 8
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September 2014
MASSIVEREEwww classicford
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Your guideto go wide
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HOW TO
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26/09/2014 10:31
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20 December 2014
RATCHET WRENCH19.74 Sealey
This 3/8-inch square drivratchet wrench is madevanadium steel,
hardened andtempered, with a fully polished mirrornish. Its
72-tooth ratchet action is ideal for use in conned areas, and it
features a pear-head with ip reverse, push-button quick release and
offset handle with anti-slip comfort grip.Contact:
www.sealey.co.uk
DIAL BORE GAUGE77.94 Sealey
This is a great tool for checking the state of wear with the
piston bores in an engine block. Offering a precision mechanism
with 55 mm dial and locking rotating bezel, the gauge gives an
accurate method of measuring a bore or detecting if taper or
ovality is present. It will evenindicate the deviation from the set
sizeby up to 5 mm, with an accuracy of 0.01mm. Also included is the
probe body, dialindicator, anvils and spacer rings.Contact:
www.sealey.co.uk
ve gear-to-geare from chrome
ADE IMPERIAL R GAUGEraper Tools100 mm long taper blades, and
polished for accuracy
and long life, each blade is marked with its size and folds into
a polished steel case with thumbscrew. Blade sizes as follows:
0.0015, 0.002, 0.0025, 0.003, 0.004, 0.005, 0.006, 0.008, 0.009,
0.010, 0.011, 0.012, 0.013, 0.014, 0.015, 0.016, 0.017, 0.018,
0.019, 0.020, 0.021, 0.023, 0.024 and 0.025 inch.Contact:
www.drapertools.com
GAZ SIERRA DAMPERSFrom 61.03 each GAZ Shocks
For a car that was so popular in its day thereSierras left, but
its suspension lives on in numcompetition vehicles and GAZ can
offer adjudampers for almost all of them. The exampleis actually a
pair of GAZ dampers for a SierraRod car, but GAZ also produce
dampers forand four-wheel-drive Sierras, early (82-84) SSierra
models, estate car versions, XR and RS models. All GAZdampers can
be adjusted for bump and rebound by a knob onthe side of the damper
body. GAZ can supply the dampers setup for general road use and
they will also be suitable for occasional track slalom and sprint
use, or they can be set up for serious racing and rallying use if
you wish. GAZ dampers and inserts feature a zinc plated body with a
durable plastic sleeve for the exposed rear dampers to keep them
looking good and working well. Worth remembering if you are
planning on restoring one of the few Sierras left.Contact:
www.gazshocks.com
RS500 INTERCOOLER295 Burton Power
The benets of a highly-efcient intercooler is nothing new, and
neither is the legendary RS500-style front mount item for the
Sierra/Sapphire Cosworth. But what is new is this particular
intercooler from Burton Power. Using the latest moulded end tank
design (opposed to bent and welded end tanks) and a 60 mm aluminium
core Burton claims this
intercooler signicantly outperforms the original Ford item,
offering a temperature drop of 103.5 degrees
compared the 80.2 degrees reduction from the stock cooler.
ww.burtonpower.com
26-BLAFEELE16.77 D
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e in the photograph-based Lightningthe Cosworth twoSierras,
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CLASSIC FORD T-SHIRTSFrom 13.99
Looking for Christmas present ideas for your better half? Our
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Ford-branded t-shirts and hoodies, with multiple designs, colours
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AD
GJ
Weve seen some great feature cars in 2014, now its up to you to
select your favourite!
22 December 2014
A. Anglia 105E Owner: Steve MossFeatured: Decembeer 2013Built
from scratch by Steve, his dad and friends, this bespoke race car
is a work of art that runs a top-spec XE engine. A guaranteed
head-turner.
B. Fiesta XR2 Owner: Sean ChessumFeatured: December 2013One of
the stars of last years Great Unveiling, Seans homebrewed,
Yamaha-engined Fiesta XR2 is a feat of clever engineering, that
really looks the part, too.
C. Granada 3.0S Owner: David WardFeatured: October 2014Rare as
you like, and achingly cool, Davids restored Mk1 sits superbly over
those banded steels. It sounds great thanks to the Burton
Power-built 3.1 Essex
D. Escort Harrier Owner: Cyril HughesFeatured: March
2014Restored as a tribute to his late brother, this Harrier is now
better than new, and proof that sometimes classic Fords are best
left alone.
E. Thames 300E Owner: Rob DowlingFeatured: December 2013You cant
beat a well-modified Thames, especially one thats
running a 2-litre Zetec on bike carbs. Robs homebuilt 300E gives
new meaning to the term, rapid delivery.
F. Capri 3.0S Owner: Wayne ChampionFeatured: May 2014If you
described your dream-spec Mk3 Capri, the chances are Waynes
throttle bodied, Cossie 24-valver dripping with Series X goodies
would be it. Stunning.
G. Escort RS2100 Owner: Steve CroppFeatured: Summer 2014Part of
our Class Of 2014 line-up, this Escort has it all, with a different
take on the RS2000 livery and exquisite attention to detail. One of
our favourite Mk1 Escorts of recent years.
H. Anglia 105E Owner: Tom CroppFeatured: July 2014Like father,
like son, Toms created this unique, arched 105E built to roam the
road and strip thanks to a top-spec Crossflow. Fast, and
showstopping.
I. Thames 400E Owner: Malcolm MidgleyFeatured: Summer
2014Notoriously difficult to restore, nevertheless Malcolm went the
distance, turning this once-rotten Thames into a rare and cherished
example of Fords early 60s commercial classic.
J. Mk1 Cortina GT Owner: Tony BarrowFeatured: January
2014Dripping with period 60s cool (and parts), Tonys Alan Mann
Racing-liveried Mk1 looks the part and and sounds it, too, thanks
to a Throbnozzle Racing Pre-Crossflow.
K. Mk1 Fiesta Owner: Christian PikeFeatured: Summer 2014Inspired
by the awesome 1979 Monte Carlo-spec works Fiestas, Christians
built this cracking tribute, only with more-modern running gear and
even better looks.
L. Mk1 Capri Owner: Dave MagenisFeatured: August 2014Restored
not once, but twice by Dave, this Mk1 has all the right ingredients
for a classic early Capri with a fruity Pinto, uprated running gear
and drop-dead gorgeous body and paintwork.
HOW TO VOTEChoose the car you want to vote for from the
selection above, then head online to our website at:
www.classicfordmag.co.uk and follow the instructions.
Voting closes November 14, 2014.The winning car will be revealed
in the January 2015 issue, on sale December 5.
FOR YOUR FAVOURITE
201
CAR OF THE YEAR
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B C
E
F
H IK L
LAST CHANCE
TO VOTE!
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26 December 2014
MK2 ESCORT
Just how do you fit a 400 bhp V8 from a dead Australian Monaro
between the front wings of a Mk2 Escort? Read on and find out!Words
Jamie Arkle Photos Adrian Brannan
Aussie
Rules
-
popular v8
December 2014 27
s there anything better (in the car world at least) than an
engine swap? Theres nothing to touch physically transplanting the
heart
from one car to another, both in terms of the added performance
itll almost certainly bring, and because of the sense of
achievement it entails. There isnt much you can do to a car thats
more rewarding than a successful motor swap and, more often than
not, one leads to many other, more complex exchanges further down
the line. Of course there are a number of set menu swaps in the old
Ford world, and, though well most certainly never tire of seeing
Zetecs and YBs transplanted between the wings of Escorts, Capris
and Cortinas, theres also something to be said for going off piste
and
doing something totally different, something seriously
challenging.
Enter stage left, Finlay MacPherson, the owner and builder of
this monstrous Mk2 Escort, a car with the kind of engine to make
Ford purists break into a sweat, and leave the rest of us
slack-jawed with awe.
I set out with a project car in mind, but at the start I just
wanted something old and rear-wheel-drive that I could put a
powerful engine in Ive got a thing for making old cars go stupidly
quick, Finlay laughs.
Blast firstIn late 2011 an Escort shell was located, a bare,
rolling one with an X-pack kit thrown in for
good measure. The seller had given it aonce over with a coat of
primer, so it actuallylooked a lot better than it was, and it was
only when he got it home, removed the kit and had a good poke
around the Finlay discovered just how much work hed given
himself.
A shotblasting session painted an even clearer picture, with a
list of areas that needed urgent attention running to the rear
three-quarters, the boot, the oor, the chassis rails and the sills
everything bar the outer skin. The one silver lining to all this?
It gave Finlay the opportunity to strengthen the whole front end
and add a comprehensive cage, an important addition, as by this
point hed decided what kind of propulsion the car would have.
I
I SET OUT WITH A PROJECT CAR IN MIND, SOMETHING CLASSIC AND
REAR-WHEEL-DRIVE THAT I COULD PUT A POWERFUL ENGINE IN
Heroes!
HybridS P E C I A L
ENGINE SWAP
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Rollcage is comprehensive, andconsidering Finlays alreadyhadone
incidentwith thecar,probably very necessary!
Original dashhad to go, so Finlaymadeupanalloy one to go in its
place. TrickRaceTechnologydigital display cuts downon theamount of
gaugesneeded.
17 inch ImageBPSsplit-rimsll theTarmacarchesnicely.
28 December 2014
MK2 ESCORT
It started out with an evening browsing the internet, then I
spotted a crashed 2004 Monaro near Birmingham. The idea of a V8
Escort sold me the LS1 there and then, and I headed down with a van
and a load of tools.
Freeing the engine from its Aussie home was simple enough, and
before long Finlay found himself with the LS1 and gearbox sitting
next to the car, trying to work out how on earth to splice the two
together. Hed taken a few measurements from between the strut tops
so knew that it could physically t, but wasnt sure how much
bulkhead hed have to cut away. Of course, tting an engine this big
into a small, 70s Ford was always going to throw up obstacles along
the way, and weve covered the tting process in greater detail in
the boxout. Sufce it to say that packaging was the biggest issue;
Finlay could get the V8 in place, with the leading cylinders just
behind the Escort struts, but successfully packaging the various
ancillaries took a lot more work.
Heading up The biggest issues Finlay encountered were the
headers and the steering column, and both had to be modied to work
with each other and within the connes of the shell. Curing the
former involved buying an aftermarket part from the US that looked
right, then notching the chassis rails to accommodate it. This
eventually led to Finlay plating and strengthening the whole front
end, from the foot of the drivers seat to the slam panel. There was
no room at all for a steering column between the headers and the
block, so Finlay ended up making a hybrid out of various old Escort
ones, with roller bearings at one end and a sleeved centre section
for strength. He then had to remove an excess casting from the
block and space out the head and manifold ange by a few
millimetres, all to allow just enough space for everything to
sit.
It took a lot of work, loads of cutting a welding. Ive near
enough remanufactured the entire front end and transmission tunnel,
with just the outer skin and the location of the front struts left
as Ford intended, explains Finlay.
The rear end was, if anything, even harder, and thats despite it
consisting of hardware a lot more familiar to your average Escort
builder. The Monaros rear end wouldve been ridiculously big for the
Mk2, so Finlay instead opted for a Fostek-built Atlas, with a
beefy, custom prop leading to a the Tremec six-speed box. Making
all that t eventually resulted in Finlay semi-spaceframing the rear
end, with new chassis rails and a boot oor built around the
mechanical components. This also allowed
-
So,howdidhedo it? Finlayusedcustommounts toget theenginein
thebay,with the front endof theblock eventually resting in linewith
theEscort strutmounts (idealforweight distribution).Thatmeans that
thebulkheadhastotally gone,alongwith any traceof theoriginal
transmission tunnel.Finlayhashad tobuild all theseessential bits
around thedriveline,with theentire front endstrengthenedwith
3mmplatingandanew, recessedbulkhead setmuch further back. Itmight
soundsimple,but the really taxingaspectof thebuildhasbeen
squeezingthemanifolds andvariousancillaries into thebay!
FIT IT:LS1 INTO MK2 ESCORT
Camber-adjustable top mounts set the Escort up for track
work.
15-gallon fuel cell needed to cope with the LS1s thirst.
It was a lot of work for Finlay, but the LS1 is in the hole and
its not going anywhere. Note how much of the bulkhead had to be
remade.
popularv8
Six-linked, Fostek-built Atlas axle is man enough to cope with
the V8s grunt.
Heroes!
HybridHybrid
S P E C I A L
ENGINE SWAP
December 2014 29
-
him to site the Group 4 six-linked rear endexactly where he
wanted, an importantconsideration as he wanted the nished car to
goin roughly the direction he pointed it!
The build progressed apace, to the pointwhere Finlay soon had
the car dry built, with theengine, transmission, brakes and
suspension allin situ. He then promptly hauled it all out andsent
the bare shell off to a local rm to beprepped and painted.
Id asked the fella not to go too nuts withthe nish, as this was
always going to be a car tobe used hard. I got back to nd that hed
goneto town on it though, and the nish really wasstaggering Id
ended up with a show car!
Big grinsWith the end in sight, Finlay sent the freshlypainted
Escort (now reunited with its runninggear) to Ben Lord of Crosshill
Sports andClassic Cars to be wired up and MoTd. Wedont know what
his expression was when hegot the completed, road-legal car back,
but weimagine he was grinning like a Cheshire cat and who could
blame him; he now had a V8Escort, good for 400 bhp and
435lb.ft!
Sadly the tale doesnt end quite there and, inFinlays own words,
there was a twist, orrather a spin.
Expect to see car and owner on a track near you soon.
Spot the details: fuel ller has been relocated higher up.
How hard does this look?
It was only the third time Id driven the car, it was a dry day
and I wasnt pushing it... I just got caught out coming off a
roundabout and spun it into a hedge, just missing a lamp post,
sighs Finlay.
Gutted doesnt even come close to expressing how Finlay felt, but
he wasnt put off. The accident happened in April, and by July
(after months of arguing with his insurers, some bodywork and
another coat of paint) he was back out in it, the Escort looking
better than ever. Hes now in the enviable position of owning one of
the mightiest rear-wheel-drive Escorts in the UK, with track days
booked in for next year, plus plenty of shows all over the country.
Over 400 bhp in a car weighing 1083 kg? That sounds like a good
recipe to us!
THE PAINT FINISH WAS STAGGERING IVE ENDED UP WITH A SHOW
CAR...
30 December 2014
MK2 ESCORT
Tech SpecBody
1976 Escort Popular shell, full bare-metal restoration with lots
of extra strengthening, smoothed rear end, fibreglass bonnet, boot,
rear bumper, steel front quarter bumpers, extra wide 15 inch Tarmac
wheel arches, link boxes, rear turrets, bespoke front and rear
firewalls, boot floor and transmission tunnel, six-point weld-in
roll cage with extra bracing, raised fuel filler cap, plexi-glass
windows all round, heated front windscreen. Weight: 1084 kg with
full tank of fuel
Engine2004 GM LS1, rear-bowl sump, Aeromotive fuel pump, fuel
pressure regulator and fuel rails, Facet lift pump, swirl pot, 15
gallon fuel tank, MBE 9A9 ECU, alloy flywheel, Griffin radiator
TransmissionLS7 Clutch, Tremec T56 six-speed box, 500 bhp-rated
propshaft, 18-spline halfshafts, Gripper diff, 3.75:1 ratio, Fostek
Atlas axle
SuspensionFront: fully adjustable front end, Gaz Gold coil-overs
with 350 lb springs, alloy hubs, front strut brace,
camber-adjustable top mounts Rear: Avo coil-overs, 175 lb springs,
fully adjustable six-linked rear end
BrakesFront: Wilwood four-pot callipers, 270 mm discs, Group 4
pedal boxRear: Sierra Cosworth discs and callipers
Wheels and Tyres9x17 inch Image BPS alloys all round, 235/35R17
Falken tyres
InteriorFibreglass seats, four-point harnesses, Race Technology
Dash2 LCD Dash, custom alloy dash, toggle switches for
instruments
ThanksBen at Crosshill Sports & Classic Cars (01356 622827),
my old man, Lachie and girlfriend, Nicola
-
Nissan SR20DETPros: Cheaper than a Cosworth YBCons: Not as easy
to t
In a lot of ways, the SR20DET is Nissans version of the mighty
Cosworth YB. A turbocharged twin-cam, 16-valve 2-litre with an iron
block and alloy head (though with chain-driven rather than
belt-driven cams), its strong and easy to tune, though features
slightly less exotic bottom end components.
Its got a lot going for it engines arecheaper to source than the
YB and routes to more power are well-known and proven. On the
downside, youll need to use a Nissan gearbox and mounting one
either involves hanging it off the chassis rails or making up your
own set of mounts.Capacity: 1998ccFound in: Nissan 180SX, 200SX,
Pulsar GTI-R, Silvia
Lotus twin-camPros: Looks the partCons: Expensive
Fords rst foray into a production twincam engine, the
Lotus-designed eight valver was based on the Cortinas 1500
Pre-Crossow bottom end, but with a cast alloy head. Blocks were
bored to 82.5 mm from the standard 80.96 mm, and like the BDA there
have been many derivatives so you need to know your stuff. For
instance, the Mk2 versions having a thicker casting to more
reliably carry the increased capacity that allowed 1558cc. These
later engines also had square mains caps the same as 711M-block
Crossows, proper oil seals as opposed to the Mk1s ddly rope-type,
and stronger 125E conrods.Capacity: 1558ccFound in: Lotus Cortina,
Escort Twin Cam, Lotus Elan and Europa
Vauxhall/Opel XEPros: Strong, easy to tuneCons: That GM
thing...
Yep, its not Ford but it is excellent but then, what do you
expect from a Cosworth KBA? The earlier Coscast engine is ideal it
comes with forged pistons, while tuning potential is almost
instant. Swap the induction, cams and exhaust and 200 bhp isnt that
far away. Or convert to SBD Motorsports complete taper throttle
body system and that power is near bolt-on. Turning to rear drive
is pretty easy too, with either Manta components (sump and ve-speed
box), or a Yukspeed sump and one of SBDs two types of bellhousing
for a Type-9 conversion. Simple.Capacity: 1998ccFound in: Vauxhall
Mk2 Astra GTE (Opel Kadett E GSi/GTE), Mk3 Cavalier GSi/SRi,
Calibra 16v and Mk3 Astra GSi
Want to know what your all-time favourite engines for dropping
into classic Fords are? Read on.
TOP 10 Your Top 10 Transplant Engines
10
9
8
CFTECH
-
1600 CrossflowPros: Easy to tuneCons: Only a 1600
The Crossow was introduced in the Series 2, Mk2 Cortina in late
1967, then revised in 1970 into the infamous 711M, sporting a
at-face head, larger followers, thicker block amongst other traits.
Tuning potential is massive a typical road-spec of around 130 bhp
using a driveable 234-type cam; meaning plenty of mid-range torque
compared to the old Cosworth A-series cams.The road topper isthe
244, giving about 140 bhp withtwin 40s. Its not tricky
swapmaterial, but the opposite-side carblocation can be a
head-scratcher.Even then, its only master cylinderand battery
clearance causing theworry. Crossows forever!Capacity: 1599ccFound
in: Most late 60s to late70s European Fords
Duratec HEPros: Modern, light and clever designCons: Zetecs are
currently cheaper to buyand t
Fords Mazda-derived, all-aluminium engineintroduced in the 2001
Mondeo is now the one to t,albeit at a cost.You wont pick one up as
cheaply as aZetec but theyre good for 200 bhp without taking
thehead off! Even then, its 220 bhp before you need toswap the
rods, crank and pistons for something a touchless production.Weigh
it all up and that power levelspretty cost effective too.The life
of this engine is in noway over the 2.3 is obtainable over here,
but morecommon in the US, while a 2.5-litres become availablethere.
Its swap potentials a touch more tricky youneed a conversion
bellhousing for a non-Mazdatransmission and a strong gearbox. Plus
theresinduction and a water rail to consider as well notcheap, but
oh so worth it!Capacities: 1999cc, 2261cc, 2488ccFound in: Mk3-on
Mondeo, Mk2-on Focus
Cosworth 24-valve V6Pros: Good looks, good soundCons: Tricky to
tune
The 24-valve was of course made by Cosworth; developing lovely
alloy twin-cam heads in much the same way as they did for the
fabulous GAA Essex-based engine.
However, in this case it is for the road - although youll only
nd one in a late Granada. And with an automatic to boot! But then
they put out lots of power from standard, are easily tuneable and
virtually bolt in where a 2.9 did. Theyre not too pricey
either.
It all seems too good to be true, and the only tricky bits nding
a gearbox with decent ratios to stand up to the grunt a hybrid
MT75s the only true answerCapacity: 2935cc Found in: Mk3 Granada
Scorpio, Scorpio
Small-block Ford V8Pros: Massive range of tuning partsCons:
Weight, fuel-consumption
Big?Well, its not that large. In fact, its smaller than a Rover
and only a tad longer than a V6. And heavy yes, in standard form,
but replace most of the components with aftermarket alloy and it
drops like a stone. And to be honest you cant get much more classic
Ford than a small block Mustang, Cobra and Le Mans friendly, theyll
give you stupid power from standard, mental with mods and torque to
rip out your lungs...
Its roots go back to the 1962 Fairlane, which introduced the
Windsor V8, named after the engine plant in Windsor, Ontario. The
famous ones are the 289 and the 302, latterly called the 5.0. And
theres more available to tune them than the chip shops got
chips.
To t one into your classic (British) Ford youll need fairly
extensive fabrication skills apart from the Capri where, if you
take care to choose the right parts, they virtually fall
in.Capacity: 221 cu.in, 260 cu,in, 289 cu.in, 302 cu.in, 351
cu.inFound in: Most US Fords from 60s onwards
7
6
5
4
December 2014 33
top 10 transplant enginesHeroes!
HybridHybrid
S P E C I A L
ENGINE SWAP
-
2-litre PintoPros: Easy to tuneCons: Getting harder to nd
Probably Fords rst World engine, the Pinto is named after the
small US car that introduced it in 1970, then we got it too in the
new Mk3 Cortina. The 2-litres the most desirable engine, but even
then, its really only the Sierra injection 205 block thats the
current viable base for a performance plant. These mainly have
unleaded heads, although the valve seats need properly checking -
they can fall out! Tuning potential is huge 130 bhp is easy with a
cam and induction change, while 180 bhp isnt that far away either.
A big-valve head, twin 48s, high-lift cam and high compression
should see this gure. Swapping is straightforward on rack-equipped
cars they all have a rear-bowl sump and most use bolt-in RS2000
components. Note though, the carb and exhaust are on the opposite
sides to Crossow-engined cars.Capacity: 1993ccFound in: Mk3-Mk5
Cortina, Capri, Sierra, Transit
Cosworth YBPros: Power is almost limitless
Cons: Expensive to buy, rebuild and tuneYes, they may well cost
a fortune to buy in the rst place, especially a good, legit one,
but they take the minimum to wire up and virtually bolt in place of
a Pinto. Plus keeping the turbo means an easy 200-plus bhp, and the
tuning potentials incredible bhp gures are almost limitless. But
they have a serious reputation for normal aspiration, too. Prior to
the 1986 launch, the YB was a Cosworth venture to convert the Pinto
into a BDA beater alloy head, 16-valve, twin cam - the next-step to
conquering the rally world. It didnt quite work out that way but
there are plenty of NA Cossies competing and powering road cars.
The typical built gure is around 225 bhp but its at a cost and the
conversion isnt as cheap as some of the more up-to-date options
like the Duratec.Capacity: 1998ccFound in: Sierra/Sapphire/ Escort
RS Cosworth
ZetecPros: Easy to nd, and tCons: Conversion costs
There are basically two series of Zetec the Silver Top and the
Black Top, while the cooking ST170 is based on the latter - its
American though and quite a bit different.
The Silver Top is known as the Mondeo engine, while the Black
Top is the Focus engine, and both produce big power with an
induction change. You can get up to 150 bhp with the standard
breathing components and around 170 with carbs/injection. 200
bhp is hard without headwork and larger-size followers, which are
needed for longer duration cams.
Zetecs will mate to any Ford-pattern gearbox, so theyre easy to
turn round but you will need a water rail conversion, correct
rotation water pump and ideally, a rack-and-pinion equipped car.
Front bowl sumps are available, but not many choose this
routeCapacity: 1796cc, 1988ccFound in: Focus, Mondeo
3
2
1
CFTECH
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HOMEBUILT HERO
36 December 2014
BACK
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anglia st170
December 2014 37
When Steve Osborne came across a rare, base-model Anglia, he
know just what to do build
the 16-valve Tarmac terror he always wanted.Words Marc Stretton
Photos Jon Hill
unning and modifying Anglias has been in the blood of Steve Ozzy
Osborne for four decades. He ramped one round
the elds before he was old enough to drive then bought his
uncles 105E as a rst road-legal motor. Most of my mates were in
quicker Escorts and the like, he says, so I had to have a go at
modifying my Anglia you know, 1500 motor, and things just went from
there.
At least 10 Anglias have come and gone over the years, and there
are still several on a eet of a dozen old Fords that cant be parted
with two of these having Lotus twin-cam conversions and another has
just 30,000- miles from new.
Theres a problem with running old-school Anglias though,
especially when you like to use them to their full potential (as
Steve does), and thats reliability. After a piston broke on one of
his Lotuses back in 2010, thoughts turned to the possibility of
going for a new car for trips and tracks, with a modern powerplant.
So the
search was on for something to go for a Zetec engine conversion
with.
Too goodMy rst attempt failed miserably, Steve admits. I bought
a 1200 Super, but once looked over, it was too good to mess with.
The body was very sound, the interior excellent and when I pushed a
cassette into the 8-track and it worked, that was it! So I now have
another nice, original car in the collection...
Soon a second possible contender turned up in the classieds, and
this was more promising. A rare base model 1964 Anglia solid, but
obviously in need of a bit of bodywork. Having the van-type
front-end was a great draw, says Steve, and I think the seller knew
he had a deal on when I turned up for the viewing with a trailer.
The car drove onto the trailer, but when I got home, it refused to
start. That was it... this was the one to be Zetecd.
It would be a couple of years before Steve
R
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HybridHybrid
S P E C I A L
ENGINE SWAP
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Lack of bumpers, Superlites and cage all add to the Anglias
street racer pretensions.
38 December 2014
HOMEBUILT HERO
Looks pretty good, doesnt it? Steve thought so too,which is why
he grabbed it for his 16-valve project.
Alongside the bodywork, Steve sorted all of the upgrades. The
wiring was made up by mate, Kevin.
HOMEBUILT HEROPopular engine transplants like the Zetec are
perfect for homebuild projects, as tting is usually a cinch, just
make sure you allow for the fact that the bodyshell may need work
just ask Steve...
Almost there. The Anglia in the foreground is one of a pair of
Lotus twin-cam powered examples Steve owns!
Mounting the partially-painted shell on a home-made spit meant
tting the running gear was easy.
Steves cunningly routed the wiring harness through the
now-redundant heater inlets on the bulkhead.
Swirl pot, fuel pump, lift pump and lter all live on top of the
axle hump in the Anglias super-clean boot.
Original dealer decal is a neat touch. Hodgsons in Retford were
a Ford Rallye Sport dealer, now sadly
Swept, stainless exhaust manifold looks the business.
Steves made a neat job of the Zetec install. Keeping the
pipework black makes it look like a factory install, too.
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anglia st170
December 2014 39
Zetec ST170 engine looks right at home. Modied head and throttle
bodies mean power is well up on standard.
Type-9 box swap meant a new transmission tunnel was needed.
Ex-MGF leather seats were a bargain 80 nd, and are
super-comfy.
Like the rest of the car, the interior is specced for hooning.
No heater needed.
made a full-on start to this project, but over that time he made
sure he collected together most of the bits he needed for the
conversion, including a low-miles Focus ST170 motor, Type-9 box and
RS2000 axle. Before that lot could go anywhere near the shell there
was some bodywork to crack on with, though.
The car was stripped, mounted on a rotating frame and... I found
out there was quite a bit more work here than Id planned, says
Steve. When Id looked over the car, a lot of the common Anglia
rust-spots were sound, so I presumed it was a pretty good shell.
Taking it apart it soon became clear that a previous owner had
helped save the metalwork by stufng oil-soaked rags everywhere.
These had done their job, but it was almost like the car had said,
OK if you wont let me rot there, Ill just go ripe in some unusual
places! The oors, rear arches, valances, A-posts and headlamp bowls
needed major work, plus there were lots of small patches to be let
in all round.
So a weldathon began, but with help from mate, Ian Hogg the
shell came together over the next 18 months. With most of the
engine, suspension and brake conversions already planned,
fabrication work for the ST engine (modied bulkhead), Type-9 box
(large tunnel) and Milton rear damper kit was all done before any
paint was applied.
Back in shape, the Anglia briey left Steves garage for Ian to
expertly lay on the Caribbean Turquoise paint.
Dropping a Zetec or ST170 motorinto an Anglia really is a piece
of cake these days as some clever blokes have worked out exactly
the best way to do it, and designed kits to make life every easy.
Milton, Retro Ford and 105Speed are the rms you need to get in
touch with.
Milton do a World Cup crossmember to allow for a rack
conversion, and then youll need engine mounts and a front-bowl sump
from Retro Ford. Spinning the front-drive motor through 90 degrees,
causes grief with the cooling system but a Retro Ford water-rail
kit solves all these problems, and a re-cored Anglia rad or VW Polo
item will keep temperatures down. Engine clearance issues sometimes
occur at the bulkhead, which needs recessing slightly, and if twin
carbs or throttle bodies are used the master cylinders will need to
be relocated.
Custom exhaust manifolds and pipes are available from many
sources, with 105Speed having a range of systems, and its also a
good idea to look into starter motor and alternator kits. Matching
up a clutch and transmission can be tricky, with the option of
alloy bellhousing, Pinto clutch and Type-9 ve-speed being a common
route.
Download a 10-step guide at www.classicfordmag.co.uk.
96 Summer 2013
CFTECH
Swapp ng a Zetec nto anAng iadoesn t have o be expensive In
facttheres now an almost set ormu awo ked out by the var ous specia
stsand orums or the model plus a fewspec c pa ts that wi l make he
wap abol - n ob among t others a med tomake your l fe a lot ea ier
espec al yif you want a ve speed gearboxbehind it
But he b g ques ion is whether ore ain the stee ing box or not f
t sthe la ter hen heres a mass of ki s to
v r ual y bo t in a ack and p nionconve sion w thout a te ing
the shellBut t s no the cheapest opt on eta ning the orig nal set
up s ar more
cos eff ct ve even with a vespeed! P us if we e al ing budgetyou
don t s r ct y ne d o swap theuel ing syst m to twin sided
aught
ca bs or hro tle bod es e ther dohis and it l mean mov ng he
master
cy inde s We l cover the bases buthere rea ly is an easy ow
budget wayo 16 valve power
1. Engine choiceIf DIYs your thing, you can make mounts off the
original crossmember. The more sorted route is to use a chassis
mounting kit. But for an easy life and a better result, swap the
original front crossmember for a Milton World Cup converted unit.
Couple this with mounts from Retro Ford Ltd the engine will be
pushed a touch forward but its the simplest way.
4. CoolingThere are several options here depending how much you
want to spend there are bespoke units available from the various
specialists, but the most common budget route is to use a VW Polo
radiator. However, its best to relocate the battery to the boot
most will do this anyway but it saves altering the battery tray.
Dont forget that you will need an expansion tank and pay attention
to that plumbing!
5. ExhaustSince the engine wasoriginally front-d i e mos ofthe
standard exh us s aretotally unsuitab e and wi lneed a purpose
mademanifold and sys em to inthe con nes of he en inebay. Anglia
spe ia i t105Speed has v r ua ly llbases covered n t isrespect, its
parts wo k we land are a good oo ing o t on again money spe t in
heright areas and y ur Ze ecAnglia life will be or ed
3. Water railZetecs were front-wheel-drive so they need turning
round to t the Anglia, which also means the standard thermostat
housing will clout the bulkhead. There are two solutions: Retro
Ford Ltds water rail, which needs a small pocket fabricated below
the bulkhead lip, or Racelines which doesnt. Ideally, the Zetec
plumbing should be replicated as far as possible its quite complex
but it works!
2. SumpThe original Pre-Cross ow uses a front-bowl sump in
conjunction with the original front crossmember. So if you retain
the steering box, youll need to replicate this layout, even with
Miltons World Cup crossmember. A Mk5 Escort alloy sumps an option
but its not ideal as it still needs modifying. Cash spent in the
right place is the solution, and Retro Ford Ltds fabricated
front-bowl steel sump is meant for the job.
ZetecintoAnglia105E
Swap it
4
7
6
8
How to give your 105E 16-valve power.
Wor
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on H
ill P
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hris
Wal
lban
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TERROTWINCengine swap guide
Summer 20 3 97
6. InductionTwin sidedraughts are the popular route to unlocking
power but you will need to move the master cylinders, dictating a
Milton pedal box. A cheaper alternative is a twin-choke downdraught
plus an aftermarket inlet manifold. There are several, both cast
alloy and fabricated steel, and these are suitable for around 135
bhp. Options for spark are an ECS unit or an ignition-only system
such as MegaJolt or Omex 200.
Clutch andflywheelUse a - i re en ine nd the ig w eel a d clu ch
a semb yis really only suited to a standard bellhousing set up. The
best production ywheel option (with the pick-up for the crank
trigger cast into the back) is that from an 1800. Commonly, these
are re-drilled to accept a corresponding clutch/release according
to the box youve used there are standard set ups including Pinto
clutch with a Type-9.
GearboxA f ur sp eds the easiest s lu i n the Zetec be hous ng
pattern matches. A Type-9 ve-speed ts either use a Retro Ford Ltd
bellhousing, shifting the starter motor so it doesnt clout the
steering linkage, or a Milton adapter parts, plus a 997cc
bellhousing allowing steering idler and Pinto clutch clearance. The
gearbox tunnel will also need enlarging and a custom prop made
8 Brakes andsuspensionAng as us d rum b akes sohe bes ro te o di
cs
involves adapted Mk2 Cortina front struts coupled with modi ed
TCAs the lot can be sourced through Milton although the struts are
shortened Gaz units with smaller ID coil-over conversions. Disc
brakes can now be tted using virtually any strut-based Ford strut
of this type; including 2.8 Capri vented discs.
7. AncillariesStandard alternators are massive and often
interact with the ECU which youll probably lose! Plenty of
conversion kits to retro- t an ACR-type unit exist and are dead
simple. If youre using the later Black Top Zetec then youll also
need to swap the water pump for a more conventional rotating
assembly. The coil pack will also need relocating once again, kits
for this task are easily sourced.
1
2
3
5
FIT IT:ZETEC INTO ANGLIA
I WAS GOING TO FIT THE ST170 AND LEAVE IT STANDARD BUT A MATE
WHO WORKS
AT COSWORTH HAD OTHER IDEAS
Heroes!
HybridHybrid
S P E C I A L
ENGINE SWAP
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Bolt-on bitsBolting up the Milton crossmember, rackconversion
and suspension, and Wilwood fourpots was easy, as its all proven
kit and the RSaxle went in with an LSD tted, and
Sierracallipers/Fiesta discs for the rear braking. Theengine was to
be no trouble either, as RetroFord Limited is just down the road,
so all itsbolt-on and bolt-in bits were used.
I was just going to install the ST asstandard, but with the
Jenvey throttle bodiesand Emerald management to boost power abit,
Steve says, but another mate, Pete Haley,who works at Cosworth had
other ideas. Heinsisted I let him have the head and inletmanifold
for some work. Im not sure exactlywhat hes done, but its pretty
special as Imnow running well over 200 bhp with virtuallyno other
engine upgrades, apart from aRetro Ford manifold and a custom
2.5-inchsystem I made myself.
More help came from yet another mate,Kevin Rowland, who works
for Red Bull Racing Steves got some connections and thewiring loom
and fuse/relay board Kevin hasmade from scratch is one excellent
piece ofwork, and would have cost a fortune if Kevhadnt volunteered
his services.
Retro racerThe Anglias style is full-on retro-racer, with
theexterior dechromed, debumpered and withsome Superlites tucked
under the arches, withjust a slight drop all round. Inside theres a
rollcage, some 80 bargain MGF seats (for comfort
Tech SpecBody
1964 105E Anglia Standard (base model) shell, large gearbox
tunnel, modified bulkhead, debumpered, 105Speed propshaft and
heated front screen, custom Super STeed badging. Paint: Ford
Caribbean Turquoise
EngineFocus ST170 Zetec, standard bottom-end, Cosworth modified
head, Jenvey inlet and throttle bodies, Emerald ECU and VVT
controller, custom loom and fusebox, Retro Ford sump, mounts,
water-rail and exhaust manifold, Bosch high pressure pump, Facet
lift pump, custom swirlpot, modified Anglia triple-core radiator.
Power: 200+ bhp, 170 lb.ft torque
TransmissionType-9 five-speed, Retro Ford lightweight flywheel,
Pinto clutch conversion and aluminium bellhousing, RS2000 axle with
LSD and 3.54:1 final drive, Burton Power quickshift
SuspensionMilton crossmember and steering rack conversion,
Milton front adjustable legs and top mounts, alloy strut brace,
Milton rear damper conversion, A-frame axle location kit and
anti-roll bar, 1 inch lowering blocks, polybushed throughout
BrakesFront: Wilwood four-pots, crossdrilled vented discs. Rear:
Sierra calliper conversion, crossdrilled Fiesta discs. Milton bias
pedal box, braided hoses, Fiat fluid reservoir under dash
Wheels And TyresSuperlite 6x13 inch alloys, with Yokohama
185/60R13 tyres
InteriorRear roll cage, MGF seats and inertia belts, Aldridge
door trims and headlining, Elliot rev counter, Racetech oil
pressure and water temp gauges, Mk3 Escort gearlever surround,
original supplying dealer sticker on dash
ThanksMy wife, Debbie for choosing the colour and kicking me out
to the garage when I was flagging on the project, Ian Hogg from
Andy Gormley Cars, Dave Colledge at Retro Ford Limited, Dave Walker
at Emerald, Kev Rowland at Red Bull, Pete Haley at Cosworth, Dave
at Hi Tec, Trevor at Denny Engineering, Brian Webb for sorting my
starter issues, Alan Peters for the headlining, and Michael, who
was in prison, but I dont know where he is now...Special thanks to:
Sywell Aerodrome for the shoot location,
www.sywellaerodrome.co.uk
on long runs, as Steves no big fan of trying tot in and survive
long journeys in bucket seatsanymore). The Elliot rev counter and
Racetechgauges were also a steal, as they came with aLotus Cortina
speedo Steve was after foranother of his cars 80 again bought all
ofthose dials! And then the steering wheel was forfree as he found
that in a container at work.
Aldridge Trimming door cards and aheadlining have recently been
added to smartenthe cabin, the latter being tted by Alan Peters,who
is meant to be retired from the trimminggame but seems to enjoy
helping on projectsstill. One nal touch, is the original
dealersticker on the Anglias dash.
I painted round that, rather than removingit, Steve says. Its
part of the cars history, plusI thought that if I ever get to show
the seller thenished Anglia, hed never believe it was thesame car
without seeing that.
Proving groundFor sure, this project is a far cry from
Stevesusual classic-tuned motors, but its been builtfor a purpose a
motor to have a lot of fun in and has already proved itself well up
to thejob. A rst trip out was to Anglias At The Ace inJuly this
year, and then the real trial came atSanta Pod Raceway with 19 runs
made in oneday all in the 13s at about 100 mph.
Thats exactly what I was after, Steveconcludes with a smile. Im
pretty sure Iwouldnt be doing that in the Lotus-enginedcars without
some serious worries and expensivebreakdowns happening!
ECU and relays neatly hidden away in the glove box.
Elloit tacho needed to keep tabs on the ST170s revs. Milton bias
valve controls the front and rear disc set-up.
40 December 2014
Zetec engine swap is a rst for Ozzy. We think he likes it!
HOMEBUILT HERO
ITS BEEN BUILT FOR A PURPOSE AN ANGLIA TO HAVE A LOT OF FUN
IN
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MK1ANDMK2ESCORTGomodernandyoullgofar.
GRAEMEWORTHINGTON,GS
ESCORTSTosaythatGraemeknowshisEscortswouldbeanunderstatement,andhesbuiltupmany,manyexamplesover
theyears,sowhenweaskedhimwhatchoiceofenginehedgofor,
therewasnohesitation.2-litreDuratec,withoutadoubt,hesays.Theymakeverygoodpowerfor
the
Always fancied an engine swap, but werent sure how the rest of
therunninggearshouldshapeup?Weaskfiveexpertsto
buildaFastRoad-specFordthatyoucanblastacrossEurope
inorupthedragstrip.
We can BUILD it
moneyandarereliable.Graemewouldsourceanenginemanagementkit
fromthelikesofJenveyorWeber-Alpha,andrathertryandshoehorntheMazdassix-speedboxintohispreferredchoiceofMk2shell,hesgoingforaType-9withanaftermarketbellhousing.ThoughwithaBGHGeartechgearkitwitha
longerrstgear,headds.Outback,
theresa3.54:1diffwithLSD,andtheaxlesbracedwithtrampbarsandaPanhardrod.Single
leafspringsandGazadjustabledampers,andrebuilt9
inchdrums(sonomessingaboutwithbiaspedalboxes)makeuptherestof
therearset-up.Upfront,
GraemesspeccedGazGoldcoil-oversalongwithapairof theiradjustable
topmounts,andhedalsogoforaWilwoodfour-potbrakekit
togoinside7x13RSfour-spokes.Idrunafull
interior,maybewithapairofRolltopsandnocageyoudontwant toget
toocarriedawaywitharoadcar thatyoujustwant toget inanddrive. In
fact, Id like todosomethinglike this
totakeonnextyearsClassicFordTour.
PARTSLIST:2-litreDuratec45mmthrottlebodiesandenginemanagementkitEscortDuratecsump,waterrail,andWorldCupenginemountsType-9ve-speedwithBGHgearkitDuratectoType-9bellhousingGazGoldcoil-oversandreardampersGazadjustable
topmountsSingle
leafspringsWilwoodfour-potbrakekit3.54:1diffwithLSDAnti-trampbarsPanhardrod7x13RSfour-spokes,175/50R13tyresRecoveredRSrolltopseats
Rolltopsessential forlong road trips.
RelativelymodernDuratecHE isGraemes choiceofengine,
runningthrottle bodies, too.
Escortsmakegreatcars for long roadtrips or regular use.
Heroes!
ybridHybrid
S P E C I A L
ENGINE SWAP
DURATECS MAKE VERY GOOD POWER FOR THE MONEY, AND ARE
RELIABLE
December 2014 43
engine swap projects
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MK1 AND MK2CORTINAYou cant beat a 60s Ford,reckons Retro Dave,
but that doesnt mean it cant go modern.
DAVE COLLEDGERETRO FORDLIMITEDRetro Fords Dave maybe best-known
for his Escorts, but hes also a huge fan of Fords 60s output on the
side and so given a free reign, hes put together a Mk2 Cortina
sleeper build for you to getyour teeth into, based around a later,
two-door Series 2 shell.
Engine choice is a 2-litre Zetec, using a new Black Top unit, as
theyre still readily available. Add a pair of cams, some headwork a
decent manifold, 45mm Jenvey throttle bodies and well-mapped ECU
and youve got a bit of poke while still retaining decent fuel
economy, he reckons. Youll need one of Retro Fords tting kits to
get the engine in the bay easily, and Dave recommends backing it up
with aType-9 ve-speed (with a longer rst gear, if possible) the
Series 2 shell makes the most
PARTS LIST:New 2-litre Black Top ZetecModied head with Fast Road
cams45 mm throttle bodies and ECUStainless-steel manifold and
bespoke systemWater rail and alternator tting kitsRecored original
radiatorType-9 ve-speed with 2.9:1 rst gearAdjustable platform
front strutsSteering rack conversionReverse-eye single leaf
springs1600E radius armsHeavy-duty halfshaftsLimited-slip
diffFour-pot brake kitBrake bias pedal box7x13 Rostyles, 185/60R13
tyres
MK1FIESTAIts Zetec all the way if you want a cracking Fast Road
Mk1, reckons Mike.
MIKE JOHNSONFIESTA ADDICTFiestas are already nimble lightweight
little cars in standard form, but with the right bits they can be
transformed into rapid fast road cars, reckons Mike. With the
emphasis on reliability, its important not to overcomplicate things
under the bonnet, so for me a normally-aspirated Zetec would
provide ample, reliable power and still cruise happily on a
motorway.
sense here as this box will t without cutting the tunnel.
Diff-wise, Dave recommends a 3.7:1 ratio (good for acceleration but
not too tedious on the motorway), and heavy-duty halfshafts and an
LSD are a must.
To help the Cortina handle and stop with its new powerhouse,
Dave would go for a rack conversion (but retaining the Cortina
struts using one of his new kits under development), and a
proprietory four-pot brake
kit designed to t inside 13 wheels. At the rear hed t uprated
dampers, 1600E/Lotus radius arms, reverse-eye single leaf springs,
but keep the standard drums. To retain the sleeper effect, hed t
Rostyles, banded to 7 inches wide, with some decent 185/60R13
tyres.
Dont forget some decent modern seats, too, he adds. The standard
seats look great, but theyre bloody uncomfortable on big road
trips!
Dave Colledges choice would be a Series 2 Mk2 Cortina.
Engine is a 2-litre Zetec based around a new Black Top
assembly.
44 December 2014
FAST ROAD BUILDS
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engine swapprojects
ANGLIA105EThe classic Anglebox is ripe fora transplant as long
as youchoose the right engine.
DAVE FISHERD&DDEVELOPMENTSNo16-valvershere,Davereckons
ifyouwant
tobuildagreatFastRoad-specAngleboxthenthe1500Pre-Crossowismorethanupto
the job.
Itdropsstraight in,youdontneedtomodify thebulkhead,
thebrakeandclutchmastercylinders
canstaywheretheyare,andyoucanretainall theoriginal
linkage,hereckons.Ofcourse, the1500willbeanythingbutstandard,
thoughwerenot talkingabig-bucksbuild:All
itshouldneedisabalancedbottomend,aFastRoad-grindcam,Stage2headwithsteel
rockerposts,andeithera28/36DCDor32/36DGVtwin-chokeWebercarbplusastainlesssteelmanifoldandsystemfromthelikesof105Speed,andthiswillgiveyou100bhpallday
long.Tomakethemostof
thenewengine,Daverecommendsttingthe2000Egearset
intoa1200gearboxcasing,andsourcinga3.9:1diff,as itsa
greatall-rounder.Thestandard rearspringswillbeneif they are
ingoodshape,reckonsDave, and Idtatelescopicreardamper
conversionalongwithanA-frame. Asforbrakes,good-oldM16
calliperscanbeboltedstraight on to theMk2Cortina legs,butdont
messaboutwitholdonesas new callipersarereadilyavailable.
Thesecanberunwithstandard solidorventedCapridiscs,and I
wouldkeepthestandardrear drums, if theshoesandcylinders are
ingoodshapeyoullalso needa0.750or0.875 inchbore mastercylinder.
Wheels?Mychoicewould be LotussteelsorDunlopD1s,with
185/60R13tyres.
PARTS
LIST:1500Pre-CrossowwithbalancedbottomendStage2headwithsteelrockerpostsFastRoadcamWeber28/36DCD105SpeedmanifoldandsystemAnglia/Cortina1200gearbox
casingwith2000Egearset3.9:1crownwheelandpinionModiedMk2CortinastrutsMk2CortinaorMiltontrack
controlarmsMiltonsteeringarmsTelescopicreardamperconversionA-framekit2
inchloweringblocksPolyurethanebushkitSpacedM16callipers,Capri 2.8i
venteddiscs0.750/0.875 inchmastercylinderLotussteelswith185/60R13
tyres
The cars handling is really where the benets can be had, with
coil-overs and Rose-jointed link bars, coupled with a great set of
tyres will turn my Fez into a go-kart around track. This will make
the ride a little harsher on the road, so I have decided tokeep
with a more comfortableTurbo Recaro seat option.
PARTS
LIST:2-litreZetecJenveythrottlebodiesOMEX600ECUST170exhaustmanifoldScorpionexhaustsystemIB5gearboxwithanRSTLSDttedPumagear
linkageGazcoil-oversOrbitalMotorsportsuspensionkitCompbraketopmountsXR2frontbrakesPepperpotson185/60R13YokohamaA539sRSTurboRecarosandharnessesRearSafetyDevicescage
Keep it classic: Daves ownFast Road Anglia runs
original Dunlop D1s.
1500 Pre-Crossow is a great choice for a Fast Road Anglia,
reckons Dave.
THE 1500 DROPS STRAIGHT IN AND YOU DONT NEED TO MODIFY THE
BULKHEAD
December 2014 45
Heroes!
HybridHybrid
S P E C I A L
ENGINE SWAP
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MK3 CAPRI
VEERampant rot and an expensive engine failure
might have slowed him down, but there was no way they were going
to stop David Burnell
building his dream Cosworth Capri! Words Jamie Arkle Photos
Paddy McGrath
ig, torquey V6s are very much part of the classic Ford cannon,
with many of the most popular model ranges crowned
by either an Essex, a Cologne or, in the case of the more modern
Granadas and Scorpios, a 24-valver. The characteristics of Ford V6s
are well known and well loved; effortless power, an addictive sound
and, in most cases, terrifying fuel consumption. These engines were
offered in the upper reaches of the model hierarchy when new,
though of course weve seen them retro-tted to near enough anything
and everything. That said, nowhere has the V6 been more appropriate
and more at home than in the Capri the big, hairy-chested coup was
always at its best with a V6 chugging away up front, and its these
cars that are most sought after nowadays.
David Burnells association with V6 Capris goes back a few years,
and though hed long wanted one of his own, it was only when a close
friend bought a Mk3 that he nally took the plunge himself,
eventually hunting out a solid-looking 2.8i.
It was one of those cars that looked much, much better than it
was. Once I got home and
started pulling it to bits I realised how rotten it was it was
way beyond being economically saveable, David recalls with a
grimace.
On a rollNot one to be put off by something as trivial as
terminally-rotten 80s Ford, David instead began the hunt for
another car, ideally a rolling shell that could accept the running
gear from his V6 car. One was eventually found, and the next few
years were spent transferring over the Type-9, suspension, brakes,
trim and interior, with the engine sent off to a local specialist
for a full rebuild. The new shell was actually in remarkably sound
condition, the polar opposite of the rst car, in fact! Its only
required minor welding, with one rear chassis leg and the bottom of
an A-pillar proving to be the only areas of any concern. This
allowed David to get on with stamping his own personal touches onto
the car, which explains the deleted side mouldings, rear wiper and
spoiler, the ushed bumpers, relocated and hidden front indicators,
and that custom shade of grey paint.
I was keen to make the car my own, to make it stand out from
other Mk3s, yet still be fairly
B
46 December 2014
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24-valve cosworthHeroes!
HybridHybrid
S P E C I A L
ENGINE SWAP
December 2014 47
NOWHERE HAS A V6 BEEN MORE APPROPRIATE AND MORE AT
HOME THAN IN THE CAPRI
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Black interior adds to the Caprismenacing appearence.
Capri looks great and must soundgreat on the Irish lanes,
too.
48 December 2014
MK3 CAPRI
subtle and stock looking, hence all the custom bodywork
tweaks.
All was going to plan, and it wasnt long before David was ready
to re-install the Cologne, re it up and take the newly resurrected
Capri to its rst show, which is where things began to go seriously
awry.
It drove all the way there with no issues at all, only for the
bottom end to die on the way home! It did all the bearings and we
found a loose piston crown sitting in one of the bores, so itd
obviously not been put together very well, says David.
Put awayAs you might expect, David was more than a little
annoyed, and the Capri was subsequently tucked away for the next
six months while he worked out his options and whether or not to
persevere with the project. Thankfully he did, eventually nding
fresh inspiration in the form of another engine swap, opting to
upgrade to a Cosworth 24-valve V6 from a Scorpio. Of
course, in the UK, BOB/BOA swaps are fairly common, especially
as its the logical upgrade for the Mk3 Capri, with plenty of advice
available online and via various clubs. In the Republic Of Ireland
its slightly different, with the vast majority of 24-valve-shod
cars having been bought like that, either from England or Northern
Ireland. This meant that David was going to have to rely on a mix
of forum advice and the help of his friends. Not that David was in
any way put off, and it wasnt long before he found himself
collecting a tired Scorpio donor car, complete with a low-mileage
BOB.
Weve covered the swap in greater detail in the boxout on page
49, but Davids car shows just how worthwhile and economically
viable this swap can be, especially as hes been able to
maintain his Capris original Type-9 gearbox. OK, so the Type-9
is at its limit with Cosworth power, but Ive yet to have any
issues, plus Ive got three spares in the garage, so if it does
throw in the towel then Ill just replace it, David laughs.
The wireThe physical swapping of the engines was a relatively
painless affair, despite David opting to use the later BOB instead
of the more commonly selected BOA. One of the only issues involved
the looms; David had to make a BOA loom work with his engine,
something that entailed lots of ddling and many long nights spent
poking around with a multimeter! He eventually wound up with a
pared down-loom
FITTING THE COSWORTH ENGINE WAS A PAINLESS AFFAIR, DESPITE
DAVID
OPTING FOR THE LATER BOB VERSION
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24-valve cosworth
Fitting the Cosworth-developedV6 to yourCapri makes perfect
sense, and its one of the most easily accessible engine
conversions, thanks to the small number of parts needed and the
budget nature of donor cars. Obviously, this is a simpler swap if
youre starting with a 2.8i Cologne Capri as a base, though dont let
that put you off BOA-ing a lower spec car youll just need to
convert from carb to injection along the way. The earlier BOA is
marginally easier to t thanks to its EEC-IV management, but either
can be made to work and both engines will bolt up to 2.8i mounts.
The factory Type-9 can work with the 24-valver, but it will be
operating at its limit, hence why most opt for an MT75 or T5 box,
plus a stock Cologne ywheel. As Davids car proves, the bare bones
of the original wiring loom can be made to work, though itll take
some careful splicing, or you can go all out and t standalone,
aftermarket management, something thatll stand you in good stead if
you plan on tuning the engine at a later date.
Download a more in-depth guide at www.classicfordmag.co.uk.
FIT IT:COSWORTH 24-VALVE INTO CAPRI
Subtle grey paint, Borbet Cs and an Espace front splitter Davids
Capri is more than a heavy nod to the 90s.
Mk3 dash has been given the white-dial treatment.
2.8i Recaros retrimmed in black cloth and leather.
2.8i-based brakes provide front stopping duties.
Later BOB Cosworth swap is far less common in Capris thanks to
the more-involved wiring needed, but that didnt stop David from
cracking on with the conversion.
Heroes!
HybridHybrid
S P E C I A L
ENGINE SWAP
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Tech Spec
BODYMk3 Capri 2.0S shell sprayed in custom grey, all original
panels, all side mouldings removed, spoiler, rear wiper and washer
deleted, flushed front and rear bumpers, de-badged grille, hidden
front LED indicators, Renault Espace front splitter, black bullet
mirrors
ENGINE2.9-litre 24-valve BOB Cosworth V6, K&N induction kit,
custom BOA loom, power steering system and washer bottle hidden
inside the inner wing, battery relocated to the boot, internal kill
switch, Scorpio Cosworth radiator and fans
TRANSMISSIONType-9 five-speed with quickshift and diesel Transit
clutch, 52 inch Atlas axle with 3:09LSD, one-piece propshaft
SUSPENSIONFront: Bilstein Group 4 dampers with 240 lb springs,
roller bearing top mounts, 2.8i anti-roll bar, poly bushesRear:
Bilstein dampers, single leaf springs,triangulation kit, poly
bushes
BRAKESFront: M16 callipers, Green Stuff pads, 2.8i drilled and
grooved vented discsRear: Rebuilt 9 inch drums
WHEELS AND TYRESFront: 7x16 inch Borbet C alloys, Nankang
195/4