Help Design my Spring Project MPG Car - Cash Prizes

[XFi]

SEE PAGE 2 OF THIS THREAD FOR NEW CONTEST AND RULES...WIN $100.00 IN FREE GAS!!!


Well Winter Weather is upon us here in PA. Today, was the first snow?no accumulation of course, but came down pretty good at times. This quality ?indoor time? spent in front of the computer and pellet stove brings ideas of the next spring project. Although currently unnamed, it will be a modified 1997 Ford Escort Wagon. It will have the standard 2.0 SPI Gasoline engine and the 5spd Trans (I have even toyed with the notion of an automatic since the highway gearing is a hair better). My goal will be a highway commuter car that can achieve 50mpg. I know I could just purchase a VX, but I have always liked the Escort Wagons. I have owned many escorts prior to my Metro Years and think back upon them fondly (especially the wagons).

The first step of my new project was taken and the ?salvage car? with only 18k miles was purchased from ebay and will be delivered tomorrow to my parent?s driveway (no extra space in mine ). This will be the donor engine and various other low mileage parts (wheel bearings, axles, suspension etc).

Next will be to locate a 5spd wagon with a good body. Since I have the engine and will have the transaxle rebuilt (to install different final drive) high mileage will be fine. Due to the parts car being a 1997, I will strive to find a 1997 car to simplify the swap. There were some differences in the block 98 and up with the PCV system and knock sensor.

I will utilize the winter months to accumulate info and parts to get ready for the spring?.

I want to check into replacing the power steering with a manual rack.

The 5spd Transmission (IB5) has been around for a while. I have looked up gear and axle ratios for different years and cars. I will be calling on a trans shop to swap out the 3.85 final drive gears in the standard trans for the focus 3.61 gearing. I also want to see if the 2.88 axle in the SVT 6spd is interchangeable (haven?t found info on this trans yet if it is even compatible).

I have a few items to implement on the car. Right off the bat, the engine will get a new timing belt (just in case), higher output coil and an under drive pulley. Haven?t decided about the A/C yet, but it will probably go.

Other items will include aero mods. I don?t quite know what to do besides a belly pan. Aerodynamics are not my forte. Any suggestions?

I will use this thread to update my progress and hopefully receive some suggestions on how other GasSavers.org Members would proceed. Feel free to offer your suggestions on anything pertaining to the car (engine/trans/weight reduction/etc). Even the paint job, if someone is good with Photoshop, (as long as it is ok with Matt) I will be more than willing to have GasSavers.org logo and racing stripes on the sides of the car.

Look for design competition info soon with cash prizes.

Anyway, just thinking out loud?have to go check on the pellet stove?

[lovemysan]

The 6 speed is a getrag gearbox. I read a few months back about a man who had a gear machined for his escort. I may be incorrect but he had a reverse gear machined to work as an overdrive. I also read a few minutes ago that an overdrive gear out of an 88-92 mx6 will work I think its an 0.70 gear.

[trebuchet03]

Originally Posted by lovemysan

I may be incorrect but he had a reverse gear machined to work as an overdrive.

Reverse gears typically aren't hardened as the rest of the forward drive gears are... It shouldn't be a problem, as long as you're careful

[ZugyNA]

You should be careful about reducing the overall ratio too much....there is usually a "sweet spot" as far as load vs rpm that gives the best mileage?

http://www.escortfocus.com/html/mileage_build-up.html

"The mileage test run was about 200 miles using premium fuel with about 90% highway and 10% stop and go driving coming back through a few small towns on a 2 lane road. The results was nearly 49 mpg at 60 mph (with the cruise set) on the highway with 2 people in the car. We run our mileage tests using premium fuel with the tank topped off until fuel is visible in the neck and all the air has been shook out. Then at the end of the test, we refuel at the same pump, same spot, and refill it again. We also try to do tests in 45-55 degree temperatures to prevent the gas from expanding in the tank and giving a false reading. The A/C was off and the windows were up."

* this test was run on winter gas in colder temps.

The Escort wagon is the car I'll eventually try to build up as an mpg sled.



* lower it?

* airtabs

* LRR tires?

* air dam or ???


"5 easy mods that almost always work:

-Lowering the ride
at least 20 counts of drag per inch

-Grille block (yes, in a performance mag!)
15-30 counts of drag and 50-100 counts of lift

-Front air dam (big one - from the front bumper down to the ground)
20 counts less drag, 50 less lift. more effect the taller the car is

-Seal the back of the cowl (stop airflow going under the hood at the rear)
10-20 counts of drag, 50-75 counts of lift

-Remove the outside mirrors
10-20 counts less drag.
*Except in '94-up Chevy Caprices where the Cd actually increases without the mirrors

One "count" of drag is .001 Cd, but they add up quickly"

[XFi]

Originally Posted by theclencher

nice project, an escort wagon would be one of my ideal cars too.

if i found a wagon body i'd plop my escort diesel into it

take the roof rack off if it has one

Escort Diesel...nice! Diesel was a strong consideration of mine....check out this find:
http://raleigh.craigslist.org/car/452157889.html
is actually 1200 now because he sent the head out, but the coupe has no rust whatsoever.

Originally Posted by lovemysan

The 6 speed is a getrag gearbox. I read a few months back about a man who had a gear machined for his escort. I may be incorrect but he had a reverse gear machined to work as an overdrive. I also read a few minutes ago that an overdrive gear out of an 88-92 mx6 will work I think its an 0.70 gear.

Thats right, getrag...oh well. Highly doubt compatible with the IB5.
Thanks, I didn't even think about the Mazda relations.

Originally Posted by trebuchet03

Reverse gears typically aren't hardened as the rest of the forward drive gears are... It shouldn't be a problem, as long as you're careful

Never thought about that, I will ask a trans shop about that possiblility.

Originally Posted by theclencher

http://www.gassavers.org/showthread....highlight=gear

escort gear mod, good for 107 mpg!

Didn't even catch that one before. COZX2 is way ahead of me...I guess I'll just have to tap into his experience/knowledge on this matter

Originally Posted by ZugyNA

You should be careful about reducing the overall ratio too much....there is usually a "sweet spot" as far as load vs rpm that gives the best mileage?

http://www.escortfocus.com/html/mileage_build-up.html

"The mileage test run was about 200 miles using premium fuel with about 90% highway and 10% stop and go driving coming back through a few small towns on a 2 lane road. The results was nearly 49 mpg at 60 mph (with the cruise set) on the highway with 2 people in the car. We run our mileage tests using premium fuel with the tank topped off until fuel is visible in the neck and all the air has been shook out. Then at the end of the test, we refuel at the same pump, same spot, and refill it again. We also try to do tests in 45-55 degree temperatures to prevent the gas from expanding in the tank and giving a false reading. The A/C was off and the windows were up."

* this test was run on winter gas in colder temps.

The Escort wagon is the car I'll eventually try to build up as an mpg sled.



* lower it?

* airtabs

* LRR tires?

* air dam or ???


"5 easy mods that almost always work:

-Lowering the ride
at least 20 counts of drag per inch

-Grille block (yes, in a performance mag!)
15-30 counts of drag and 50-100 counts of lift

-Front air dam (big one - from the front bumper down to the ground)
20 counts less drag, 50 less lift. more effect the taller the car is

-Seal the back of the cowl (stop airflow going under the hood at the rear)
10-20 counts of drag, 50-75 counts of lift

-Remove the outside mirrors
10-20 counts less drag.
*Except in '94-up Chevy Caprices where the Cd actually increases without the mirrors

One "count" of drag is .001 Cd, but they add up quickly"

Great Build up article...THANKS! 50mpg here I come! Automatic to boot, hopefully I can get the highway gearing done on the 5spd and do even better.

As far as the 'sweet spot', I'm sure you are right, but I want to be able to cruise 70-80mph and still get the MPG. Also, I want to minimize the rolling resistance, so I may even go with smaller brakes/rotors/wheels than the factory (for the year). Doubt I will over due it, but I will keep that in the back of my mind.

LRR tires with lightweight rims are definately on my mind. The stock tires are 185/65r14 and when mounted on the stock 14x5.5 alloy rim for the wagon/sdn they weigh approx 33lbs each (just weighed the one on my recently aquired/recieved/delivered parts car). They also have almost a 6 inch tread cross patch area. The 13x5 VX wheels that I have with Kumho 795 155/80r13 tires weigh in at 22.8lbs each and exhibit approx only a 4.5 inch tread contact patch width. I need to decide what to do with the wheels/tire combo. I could go with the HX rims that weigh in at 24.4 pounds total with Potenza RE 92 (165/65/14) LRR Insight Tires (info from SVOboy link:http://www.gassavers.org/showthread....t=lrr+hx+tires) although I have no idea what the width of the contact patch is, only that the that combo would work and avail itself to a LRR tire/size. ------- Then I start thinking, why not go with the suspension from an older escort and put it on a 97, it may fit the VX rim. Plus it would have lower rotating weight also....Then I start thinking about just getting an older wagon to begin with and installing the newer 2.0SPI engine in that...Then I start thinking about....well I guess I will stop that rant right there.

Every car I have lowered, I have regretted lowering due to the ride. Do you think it would help just putting a mild lowering spring in the front only? The front of these cars usually sits higher than the rear...this should basically even the car out.

As far as the very large front air dam...wouldn't this increase the frontal area therefore increasing wind resistance? Excuse my ignorance of aerodymanics, but just my gut response.

Question about sealing the cowl. Do you mean just the back seam of the hood, or the cowl/venting for the intake of air for the heating/air cond.? The back of the hood meets with a rubber seal when it is shut on these cars.


Thanks everyone for the comments/tips...Keep 'em coming!

Look for design competition info soon with cash prizes.

[XFi]

--------------------------------------------------------------------------------

SEE PAGE 2 OF THIS THREAD FOR NEW CONTEST AND RULES...WIN $100.00 IN FREE GAS!!!

CONTEST IN THIS POST IS SUPERCEEDED BY CONTEST ON PAGE 2 (11-26-07)
Welcome to my Aerodynamic Modifications and Paint Scheme Design Contests...TWO CASH PRIZES OF $25.00 each to be awarded!

This will be the first (and second) contest for design of my Spring Project Car. Your thoughts and ideas are very much appreciated. Additional contest to follow after winners are declared for these.

Here's how it works:

[IMG][/IMG]
[IMG][/IMG]

Take these pics and/or any other pics or drawings of a 97up Ford Escort Wagon and modify them for:
#1. Best Aerodynamic Benefits and Exterior Modification.
#2. Best GasSavers.org Paint Scheme

A Cash Prize of $25.00 will be given for the best aerodynamic modifications (with real world applications/benefits) AND a Cash Prize of $25.00 will be given for the best paint scheme.

A few rules (let me make these up as I go...and possibly edit them ):

1. Designer must be a member of GasSavers.org.
2. Designer may utilize any and all supplied photos or any other photos or drawings of a 1997-up Ford Escort Station Wagon.
3. Designer may utilize any method of altering photo or drawing.
4. Submission must include 'GasSavers.org' painted at least one time in design.
5. Designer must post submission to this thread no later than 11:59pm on 11/30/07.
6. It has not been decided how submissions will be judged yet. Either by general member vote/poll or by the members of Team Opec Busters and Matt Timion...but winner will be declared no later than 12/07/07. (Feel free to post your thoughts on who should judge the contest).
7. $Prize will be made to winner in form of Pay-Pal, Cash or Check payment and sent no later than 12/10/07.
8. Also an additional $25.00 donation will also be sent no later than 12/10/07 to GasSavers.org for permission to utilize any and all designs including paint job from this contest on my own personal vehicle. (As long as that is ok with you Matt-please PM me with your thoughts on this).
9. At least three submissions (to each contest) must be made in order for this contest to be valid. If three submissions are not made to either the aerodynamic or paint contests (in otherwords, if the contest is a dud) any and all prize monies for that contest will be kept in 'escrow' until new contest is implemented and completed.
10. Same designer may win both prizes (aerodynamic and paint) for same submission.
10?. Any and all rules are subject to change without notice and are at the sole descretion of XFi (there, does that cover me for any lawsuits?).
This is meant to be a fun contest with beneficial ideas. Feel Free get drastic and to think out of the box, but real world modifications for an everyday driver (on a budget) are appreciated.

I know there are some members that are good utilizing PhotoShop or other similar programs, well here is your chance for $25 or even $50 for just having some fun. Go To!

Also, feel free to draw(and scan) or utilize any drawings for this contest.

If you can think of anything that would make this competition better, please post your suggestions. Thanks...

[omgwtfbyobbq]

Turn it into a baja clone with a bigger bed. Ditch the rack, then cut the rear after the back seats and weld the back up completely, maybe put a pickup truck sliding window in back for sight, then add something like a pick up truck bed to the back with a taut cover of some sort. Twice the cargo capacity, and w/ LRR tires/taller gearing, 50mpg@55mph should be easy peasy imo.

[omgwtfbyobbq]

Could. But they're 'spensive and since the bed is short, nearly as much body work would be required imo. Ya know, in poking around, and from a SAE paper or two, smaller cars are much harder to make aerodynamic (in terms of Cd) than larger ones. Larger/longer cars have more room to curve and keep flow attached, while doing this in smaller ones impinges on usable room at a given LxWxH. IMO the best donor would be an older rear-ended Subaru wagon. Very reliable, 4wd, and no need to cut up an intact car.

[theclencher]

yes- the "fineness ratio" that John Wes.... I mean, toecutter liked to go on about

[omgwtfbyobbq]

eggasctly. or the derivative of the cars' shape can't exceed a certain ratio.