Mk2 Escort Group 4 Rally Car

[Brotherhood]

I've just joined the forum to get some inspiration for my.......
Mk2 Escort Group 4 Rally Car! I can't believe what I've stumbled across, I'm in exactly the same posistion with my car albeit I'm sorting the front end out at the moment. Brilliant work!

 

[rallyreturn]

I've just joined the forum to get some inspiration for my.......
Mk2 Escort Group 4 Rally Car! I can't believe what I've stumbled across, I'm in exactly the same posistion with my car albeit I'm sorting the front end out at the moment. Brilliant work!

I'm afraid it's a massive step backwards for me..!!

Got the shell to Sean at Rally Weld today, BUT as soon as he saw the turrets he knew something looked wrong...!!! Now I've never been happy with them and always suspected that they were not quite right but the news he gave me turned my stomach.



Both have been welded 40mm too low and one facing too far forward, the other too far back. The only solution will be to cut out the turrets and inner arches together with the firewall mounting brackets etc, basically everything around the arch area, 15" tubs and new turrets will then have to be welded in place.



To cap it all I also damaged the front spoiler putting the bloody thing on the trailer.



As the shell is now at Rally Weld I've decided to let Sean do most of the work and I'll just do the finishing off.



On the positive side I never did like the way the previous owner had fitted the turrets and at least I know that the new tubs and turrets are going to be fitted correctly.



Now this is not going to be cheap and I have thought about doing it myself but sometimes it's just easier to earn the money and pay an expert to do it.



Any comments appreciated as I still have time to change my mind and give it a go..!!!!!

 

[Epicyclic]

So disappointed to hear the news, what a shame you must be gutted.
FWIW I think you have done the right thing, it would have been so disheartening to have to do a job you don't really want to by the sound of it. It would also have been a bu99er if you had gone out first time and bent it due to a strange rear wheel steer effect I guess that probably wouldn't happen as when, presumably after spraying, as the suspension didn't quite fit.
At least you have the spoiler to look forward to fixing
Looking forward to seeing progress soon...

 

[Exuptoy]

Suck it up dude. It'll come good in the end.

Ok so you have a fair outlay but the upside is, this thing is gonna be worth megabucks when finished.

 

[rallyreturn]

So disappointed to hear the news, what a shame you must be gutted.
FWIW I think you have done the right thing, it would have been so disheartening to have to do a job you don't really want to by the sound of it. It would also have been a bu99er if you had gone out first time and bent it due to a strange rear wheel steer effect I guess that probably wouldn't happen as when, presumably after spraying, as the suspension didn't quite fit.
At least you have the spoiler to look forward to fixing
Looking forward to seeing progress soon...

Thanks for the feedback, having had time to think about it, the reason I bought the shell in the first place was for a hobby and to learn new skills such as welding. I wanted it to be an enjoyable learning curve and in most part time to relax and have something to look forward to in between work and family commitments.

For this reason I have changed my mind and decided to buy all the fabricated parts needed from Rally Weld and do the job myself. Not only am I going to take on this challenge but I'm also going to cut out the 4 link boxes and crossbrace, fill in the floorpan and refit Rally Welds boxes in the correct GP4 position, at the moment they are in the clubmen position as originally fitted and again have never been 100% happy with it.

Onwards and upwards....!!

 

[Bobo]

Not only am I going to take on this challenge but I'm also going to cut out the 4 link boxes and crossbrace, fill in the floorpan and refit Rally Welds boxes in the correct GP4 position, at the moment they are in the clubmen position as originally fitted

What's the difference between the correct Gp4 position and clubmen then, does that mean the 4 link boxes and the turrets?

 

[rallyreturn]

What's the difference between the correct Gp4 position and clubmen then, does that mean the 4 link boxes and the turrets?

It's the dimension between centers of the boxes, the GP4 are 800mm apart and clubmen 780 and in my case 760..!!!! With the wider GP4 dimension you have to weld a tube through the chassis legs and then use a long bolt as they are so close to the chassis you can't get your fingers in to put a nut on the bolt.

Generally clubmen boxes are a one piece box where as the GP4 is made in 2 parts fitted seperately and then welded together, much stronger to handle more power through the axle.

It's a minor thing but has been bugging me ever since I discovered that they wern't quite right. So I'll be cutting out most of the back end suspension including the tubs, I'm trying to look at the positives and at least it was better to discover these problems now before it got to paint, or even worse at the end of the build..!!!!



I know it's a waste of money and time but I do want this shell to be right, and all the parts needed cost about the same as it was going to cost me for Sean to do the cage and other odd jobs. It also means I'll be doing those jobs myself now so I spent today practicing and experimenting with my mig welder, and considering I'm self taught and have only welded what I've done up to now on this money pit the results were quite pleasing.



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It was worth using the gas as I feel more confident about what to set the welder at for different thickness material and what method works best for me.



Now looking forward to starting the mega rebuild...!!!

 

[normspanners]

If it rains just drive faster !!!

 

[rallyreturn]

Went shopping at Rally Weld..!!!! It's like Toys R Us for GP4 Escorts











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HERE WE GO AGAIN...!!!!!!!!

 

[rallyreturn]

My run of BAD Luck continues..!!! Bought a tin of 2 PK zinc primer, reversed up my drive to unload into the garage, opened the hatch and out fell the primer, lid came off and spilt the entire 1Ltr contents over my tarmac drive. In panic mode I was just about to add the hardener instead of the thinners, then when I did rinse with thinners the tarmac started to dissolve and crumble. Rushed out with the power washer and spent 2 Hrs continuously rinsing and sweeping.



Not only Have I wasted £18 on the primer but the tarmac drive looks sh*t. Oh well it might look better as it weathers,if not the wife wanted block paving anyway.



I thought I'd better stay away from power tools today but still spending the day in the garage.



Still bought a Loto ticket today, my luck has to change soon.

 

[PhillipM]

Should have just added the hardener and brushed it over the whole drive

 

[fordman]

Hope you have a better day tomorrow. I'm looking forward to getting on again, once I finish this set of nightshifts!

 

[rallyreturn]

Made some fixing brackets for the radiator and welded into position. Then cut out the bulkhead gussets ready to weld in the new GP4 dished type.





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[Epicyclic]

Thanks for the feedback, having had time to think about it, the reason I bought the shell in the first place was for a hobby and to learn new skills such as welding. I wanted it to be an enjoyable learning curve and in most part time to relax and have something to look forward to in between work and family commitments.

For this reason I have changed my mind and decided to buy all the fabricated parts needed from Rally Weld and do the job myself. Not only am I going to take on this challenge but I'm also going to cut out the 4 link boxes and crossbrace, fill in the floorpan and refit Rally Welds boxes in the correct GP4 position, at the moment they are in the clubmen position as originally fitted and again have never been 100% happy with it.

Onwards and upwards....!!

...and so things move on, as you say onwards and upwards!
****** about the paint on the drive though...
Anyway, I'll be watching how things go, your luck will change eventually!
Cheers, H.

 

[squazy84]

My run of BAD Luck continues..!!! Bought a tin of 2 PK zinc primer, reversed up my drive to unload into the garage, opened the hatch and out fell the primer, lid came off and spilt the entire 1Ltr contents over my tarmac drive. In panic mode I was just about to add the hardener instead of the thinners, then when I did rinse with thinners the tarmac started to dissolve and crumble. Rushed out with the power washer and spent 2 Hrs continuously rinsing and sweeping.



Not only Have I wasted £18 on the primer but the tarmac drive looks sh*t. Oh well it might look better as it weathers,if not the wife wanted block paving anyway.



I thought I'd better stay away from power tools today but still spending the day in the garage.



Still bought a Loto ticket today, my luck has to change soon.

man i thought i was the only one with bad luck! keep at her,your on the crest of the hill! great work

 

[rallyreturn]

I've decided to finish off the front end before attempting to replace the Tubs, Turrets and 4 links and get it to zinc primer.



I bought one of those cheap Chinese welding helmets from Ebay, boy what a difference compared to my old one, I can now see what I'm welding without the aid of a light..!!



Welded in the gussets, took longer than expected as there's a lot of shaping, I used a cardboard template to get it right and transfered it onto the gusset. Also did a complete weld along the bottom of the bulkhead plates and tided up the top welds.





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[rallyreturn]

I think I' ve done my last weld in the engine bay so zinc primed the front end, now to start the rebuild of the back end..!!!





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[rallyreturn]

4 link boxes cut out without too much damage, I'll add metal to the cut outs and start from square 1, using the right dimensions..!!!



I also managed to cut out one of the rear inner arches ready to fit the 15" tubs. Although I've only cut along the existing arch extensions the 15" template is smaller in certain areas so it looks like more metal adding to the quarter panels.





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[Cris B]

Fantastic progress

Getting to primer always feels like such an accomplishment!

 

[jpmillermatic]

amazingly clean work...keep at it!

JP