Description
Ford Escort Cosworth – Fully Built – 498 WHP on Pump Fuel – 50k+ EUR in Parts – High Potential Setup
This Escort Cosworth has undergone a complete high-spec rebuild with over 50, 000 EUR invested in parts alone, focusing on reliability, drivability and modern motorsport-grade systems.
The engine is professionally built by Kenneth Volden, paired with a fully upgraded drivetrain, comprehensive Haltech electronics package, improved cooling, brakes and suspension, and a WRC-inspired exterior.
The current setup delivers 498 wheel horsepower on regular pump fuel, with substantially more potential available on race fuel or higher boost if desired.
Below is the full technical specification:
Engine (Built by Kenneth Volden – forged, sleeved, high-boost capable)
CP forged pistons, 7. 5:1 CR, 92 mm bore
ZRP H-beam connecting rods
Kenneth Volden CNC-ported head with oversize valves
BSRT RS500SMT camshafts (cam profiles to spec)
Escort Cosworth block with 6x long studs and Darton sleeves
BorgWarner EFR 7670 turbo with Tial 0. 63 V-band housing
Turbosmart 50 mm external wastegate
Walton Motorsport CNC billet exhaust manifold
Airtec/ Hart-style intake manifold with 74 mm Bosch DBW throttle
Bosch 1300 cc injectors
Dual Bosch 540 motorsport fuel pumps (Compbrake tank)
Oversized PTFE fuel lines + DW spin-on filter
Garrett 3. 8" intercooler with custom end tanks – pressure tested to 4 bar
Upgraded radiator with dual fans and turbo cooling circuit
Big-Wing 4x4 sump with baffles
BMC intake filter
Okada high-performance ignition coils
Mocal oil cooler with thermostatic sandwich plate
Radium fuel pressure regulator with pulsation damper
WRC breather system with dedicated catch tank
Full 3. 5” > 3” exhaust with catalyst and silencers + separate wastegate exhaust
180A alternator
Measured output:
498 hp at the wheels (Dyno)
Standard pump fuel
Safe and conservative tune
Engine and turbo system have significant headroom for more power if desired
Drivetrain
7. 5” RWD differential with Quaife internals + upgraded shafts
6. 5” front differential with Quaife internals, reinforcement plate & CNC cover
Strengthened front driveshafts
Brand new Fixit 3rd gen MT75 4x4 gearbox (Martinsen Motorsport) with upgraded synchros
Bara Motorsport 60 Nm centre differential
Center-push hydraulic release bearing
TTV 9 kg flywheel + twin-plate organic clutch (approx. 770 Nm rating)
Reinforced propshaft with heavy-duty Hardy joint
Brakes & Suspension
330 mm Compbrake front brakes
300 mm Reyland rear brake setup
ABS deleted
Original vacuum brake booster system retained
Complete new brake lines and hoses
GAZ coilovers front and rear
Compomotive MO6 wheels with new Michelin PS5 tyres
Front and rear strut braces
Electronics (Full Haltech motorsport ecosystem)
Haltech Nexus R3 ECU with custom-built loom
Haltech PD16 PDM controlling lights, fans, pumps, etc.
Fully CAN-integrated system
Haltech IC7 road-legal dash
Haltech GPS
Haltech TPMS
Haltech 8-key keypad (start/ stop & programmable functions)
Dedicated wiring for brake booster, windows, cabin fan etc.
New speakers + modern 1-DIN head unit
Interior & Exterior
WRC front bumper
WRC rear wing
WRC front fenders
WRC mirrors
Morette headlights
Full carbon roof
Nuke fuel cap system
Sparco Ergo driver seat
Sparco Evo passenger seat
Custom deep rear seats with matching backrest
Summary
A fully developed, extensively modernised Escort Cosworth with a high-quality engine build, upgraded drivetrain, advanced Haltech electronics, improved cooling, braking and chassis, and a WRC-inspired appearance.
Currently producing 498 wheel horsepower on pump fuel, with a build that supports significantly more power for those who want to explore the engine’s potential.
A serious car for a serious buyer.
