As the Escort is post 1974 it needs a collapsible steering column even though it wasn't fitted with one new. Actually it is one interpretation of the rules pertaining to ADR10 but I think it is dumb not to have one rather than argue the point. I found some interwebs posts talking about guys fitting early Laser columns but having to weld joiners on etc. Then I found an obscure post where someone said they fitted an early Gemini column to a series 2 Capri. Capri and Escort shared the same rack and column. No details and no further comments. I bit the bullet and grabbed a T series Gemini column. Overall good condition and when I compared them side by side very close in length. The Escort steering wheel is offset and angled so I put the new crossmember in and the rack and fitted the original Escort column and RS steering wheel and measured it. The stock set up is severely on the piss! Anyway then put the momo and boss on and repeated the measurements. Put the Gemini column in and positioned the column where it needs to be, used the Escort boss kit and momo and it looked doable. Rang around this morning and grabbed a Gemini boss kit and then started making up a mount. Bits were cut off to make way for studs and new studs were screwed where the Gemini column mounts. Managed to take about 10mm of the off centre and angle out though you still notice it until the position becomes second nature.
The Escort rack is a 9/16" 36 spline whereas the Gemini is 5/8" 36 spline. I think I can get an adapting uni joint but if not I will split one of each and make up a new joint. The crossmember works well. Column wasnt bolted in here and needs to move over a bit.
Isuzu key barrel and steering lock are now just swarf on the floor. We are running push button ignition and switched fuel pumps so no need.
Check fit before putting the switch gear on and pedal box in.
And here is the final mock up. Wiring the XR4 wiper motor and the Gemini switch together was doing my head in until I realised the Gemini is negatively switched while the XR4 was positively switched. Dumbarse I am. Wasted an hour. No wiring diagrams that I can find for the Gemini but no excuse. Relationship between seat, pedals, wheel, shifter and switchgear is good and better than factory.
I will finish off the gearbox crossmember and engine mounts next. I have a piece of channel running across the chassis with a 90x90x110 block of hardwood holding the gearbox up and I have put packers between the sump and crossmember. Good enough for test fits. I picked up some rollcage tube and that will replace the mild steel tube I had so that will be the main component of the gearbox crossmember with some 5t plate coerced into position.
I managed to find online a Ford engineering document about the Duratec. It lists acceptable setup angles and oil sump capacities etc. For and aft needs to be within 5 degrees of horizontal either way. Ours is bang on 5 up rear to front and the nose is about 1 to 1.5 degrees high as it is sitting on the trolley so that is good. Hard to go lower without a whole new crossmember. Again. Oil sump is off a 2.3 Ranger so about an extra litre in the sump which is also a plus and another 500mL or so in the air to oil heat exchanger. I am not going to use the water to oil unit that came with the XR4 engine, cooling will probably be close anyway.