[Frank Lee]

I would suggest that the best way to approach this project is to have a plan first, and have a certain ORDER to the modifications, and to check the progress towards your FE goal with the less invasive mods before proceeding to the extreme ones and NOT vice versa. For example, we all know that chopping the roof way down and reshaping it would lower the Cd, but then you are left with severely compromised utility- especially if you are tall. If the end goal is a fuel efficient solo commuter vehicle, it makes little sense to me to start with a comfortable, fully functional 4-passenger wagon and chop it down into an uncomfortable gutted-out single passenger whatzit with little room for stuff, as it would still be much larger, heavier, and over-powered for that purpose than need be… and I would really feel bad and discouraged if after all that effort, loss of utility, and length of time the vehicle was out of service that the FE didn’t increase very much and the FE goal was still a long ways away. Rather, if a solo commuter is what is really desired and will meet your needs, forget the Ford and build a little single-cylinder trike or something along the lines of a motorized HPV or faired-in scooter or something- you will easily surpass your 60 mpg goal that way too. Wouldn’t 60 mpg in a nearly stock appearing vehicle with all or most of it’s original utility be even more impressive?

So with that in mind:

1. Clean the intake and injectors so they run at optimum tune. Maybe some acetone would clean ‘em? If in doubt have them professionally cleaned or get new ones.
2. Make sure O2 sensor is good. Might be time for a fresh one.
3. It’s already been lowered so spend some time on a good four-wheel alignment.
4. Spend some time on the brakes- make sure they don’t drag.
5. Spend some time on the wheelbearings- use light synthetic lube and set the preload carefully.
6. Do your taller transmission re-gearing- could be the best mod of them all. Use some nice light slippery oil in it too.
7. If after that the car can handle still more "gear", modify some wheels to accept skinny 155 or 165R15 radial tires- if there’s room.
8. Pump tires up regardless. I’d suggest 50 psi and you can go up or down from there.
9. If the tires are really good and your history with not having flats is good, remove the spare and jack. Carry a can of Fix-A-Flat if you feel the need.
10. If you have steel wheels, run the flattest, smoothest hubcaps you can find. Some Escort/Tempo caps are really nice and flat, stock.
11. Use underdrive pulleys if accessories are still turning too fast.
12. Remove power steering.
13. Remove A/C.
14. Remove any other belt-driven accessories you can.
15. Wire up an alternator field disabling switch; use home battery charger or solar trickle charger to replenish battery if needed.
16. If it needs a block heater, put one in, and use a timer to get 1 to 1 ½ hour pre-heats.
17. Try a hotter thermostat. If it doesn’t produce FE gains, put the original back in.
18. Use 5W30 or maybe 5W20 motor oil. Not sure if synthetic would help any.
19. Advance the ignition timing as much as you can. Probably won’t be much, if any, more than stock unless you run oxygenated fuels.
20. Make a nice grille block, perhaps with an adjustable opening for summer/winter.
21. Try a bigger/better air dam on it.
22. Try removing the passenger side mirror.
23. Try removing the passenger side wiper.
24. Try removing the antenna.
25. Try wheel skirts.
26. Try a full belly pan.
27. Try wheel deflectors.
28. Try some gap sealing. Tape or caulk, your choice.
29. Add a dashboard fuel economy minder like a ScanGauge or equivalent.
30. IF you do a lot of P&G, install an injector kill switch. If not, install a throttle lock.
31. Still haven’t hit 60? Try a header and free-flowing exhaust- the smaller the tube, the better.
32. Maybe, after all this, it’s time to consider weight loss measures. You mentioned plexi windows and gutting. I would weigh those items before I get too Gung-Ho about tossing them, as Escort stuff is fairly light already. Remember, a 100lb drop only equates to a 1 to 2% FE improvement… so 50mpg would only become 50.5 to 51! Leave the passenger seats in the garage but be ready to reinstall them if needed.
33. No more low-hanging fruit? Didn’t we hit 60 yet? Now we think about the more radical surgeries, like top chops, or boat-tails, or sleeving and destroking, or cylinder disabling, or even swapping out the engine.
34. Last but not least, velcro a Kermit the Frog to the dash, get personalized "KERMIT" plates, and name it Kermit!

Now, you can see that this order is not set in stone, for example starting with #8 and skipping around some is perfectly legit and may even make more sense than the listed order… but you get the idea.