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Ran into this at autoblog green, and thought I share a few ideas.
The Escort has a cousin in Europe that came with smalle engines. Instead of trying to ecofy a 2.0 liter engine, why not just order up a smaller 1.4 liter unit?
Also, massively replacing body panels with fiberglass parts and perhaps a custom front and rear bumper would take you pretty far.
And as far as the interior goes, custom seats made with aluminum tubing and maybe replacing inside door trim with aluminum sheet would make it pretty light. And even though just pulling out all the sound deadening material and carpet would make it light, a more usable solution would be to replace the stuff with lightweight carpeting material.
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