Mk2 Escort Group 4 Rally Car

  1. Springerdinger

    Springerdinger memoirs of the mediocre diy mechanic

    Messages:
    430
    Location:
    UK nr Southam
    Some very tidy and straight welding ,
    Can I ask what thickness steel did you use on the Y shaped assembly?

    Cheers

    Chris
     
  2. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    The tidy welding was done by Sean at Rally Weld who fabricates all the bits required to build a GP4 shell, my welding is not so straight!!!!!! I wish I could weld like him but he has 25yrs more experience than me. His Aluminium Tig welding is just as good, he really does make it look so easy when you watch him welding.

    http://www.rallyweld.com/

    The main box assy is 3mm and the gussets are 1.5mm.
     
  3. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    Finished off the Panhard assy today, now bullet proof.



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    I've also done some seam welding around the front strut areas and re-did the chassis rails as the welding was crap, just like the rest of the previous owners work!!!!!



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  4. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    I've spent a lot of time grinding down old crappy welds and trying to make nice new welds, not always successful but still better than they were.



    I picked up some sill stand tubes from Sean at Rally Weld last Week so made a start on them today, only managed to get one done and that took about 5 Hrs.



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  5. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    All four sill stand tubes now welded, next are the seat mounting tubes, another trip to Rally Weld!!!!!!



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  6. kennedy8585 Member

    Messages:
    11
    Kanada
    Look good and what are you using to cut sheet metal?
     
  7. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
  8. kennedy8585 Member

    Messages:
    11
    Kanada
    I'm looking for sometime like this but i don't think i find these in Kanada. What size gauge sheeting metal are you using on vehicle??
     
  9. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    Called into Rally Weld yesterday to buy a few more fabricated parts, Sean was busy spanner checking his MK2 for the plains Rally next weekend but still took the time to fabricate a jig to make me a tow hook for my car which only cost a few pounds, CUSTOMER CARE AT IT'S BEST, Highly recommend Sean at Rally Weld, so if you need anything for your Escort give him a ring, you wont be dissapointed.



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    After talking to Sean I decided ro seam weld around the Splash panels and floor pan, passenger side done.



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  10. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    All repairs have be done with 1mm sheet metal.
     
  11. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    Drivers side seat mounting tubes now welded in place, I'll need to go back to Rally Weld to do the co-driver side because I cut one tube too short!!!! who said "measure twice cut once".



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  12. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    Now welded in the Co Driver seat mounting tubes, (slightly lower and further back).



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    I've also cut out metal from the rear wheel arches as these areas were damaged when I cut off the roll cage strenghening plates, butt welded new metal, not worried about strengh as the new cage will be turret mounted.



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    Also cut off the horrible strut brace brackets, and my next job is to weld in the new ones that I bought as a complete strut brace kit from Rally Weld.



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  13. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
  14. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    Wasn't happy with the shut lines so re-fitted both wings, and took more time with door adjustment. Much better now so I got round to fitting the front arches and spoiler, just needs riveting and seam sealer when I have more time.



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    Gaffer taped arches and spoiler, them marked out the wing for cutting.



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  15. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    Finished off cutting the wings and the front panel to make sure there is plenty of clearance.



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    I made a dolley so that I can get the shell out of the garage for the 1st time in over a year and a half.



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    I've spent hours wire brushing the old filler from the front arches and spoiler, countersunk the rivet holes, removed the burrs, etched primed and now ready to fit when I can find the time.
     
  16. Tupers

    Tupers Member

    Messages:
    650
    Devon - England
    Love the work you've put into this, very tidy indeed.
     
  17. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    Front arches and spoiler are now riveted on, had to improvise using countersunk screws and nylock nuts in some areas as these parts were taken off the old wings and front panel and some of the fixing holes were just too big for rivets.



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    I also got round to welding on the strut brace brackets.



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    I need to weld on the heater bowl and scuttle panel next. I've managed to repair the scuttle panel but the heater bowl (plenum chamber) is beyond repair due to the previous owner cutting it out to fit a coil and the brake reservoirs.



    ANYONE HELP WITH SELLING ME A HEATER BOWL!!!!!!!!!!



    If not I'll have to bite the bullet and buy new from Express Panels at approx £160.





    I want to fit the rear arches so it looks like I'm getting somewere. I made a slide hammer to pull out some dents so I can start the bodywork.



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  18. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    Gone a step backwards!!!!!! I wasn't really happy with the front spoiler, it was too high and so the sides drooped instead of being parallel with the ground. this is how the previous owner had fitted it as I used the same holes in the arches, I did try it lower but it didn't overlap the front of the arches.



    Was going to live with it but somebody pointed it out on another forum so i have to change it. Already drilled it off but the holes are now far too big to rivet. I've welded up the holes in the front panel and ground down, just needs a skim of filler.



    I was thinking about re-fitting it by drilling between the existing holes and then filling the large holes with filler, I'd also have to add metal to extend the arches, as I have no way to weld Aluminium this would be in steel, but not noticeable with filler in the join and it's only a small section. I would also have to straighten the spoiler edge lip as it is too short to wrap around the back of the arches.



    I'll probably go plan B and buy a new spoiler from Rally Weld, at least I can get Saun to modify it to fit the arches.
     
  19. stuvy

    stuvy Member

    can you not cut/trim/shape/weld the front spoiler corners back on? what price is a brand new one against an afternoons work?
     
  20. rallyreturn

    rallyreturn Is It Finished Yet ??

    Messages:
    217
    Location:
    Pontypridd Wales
    Thought really hard about different ways to get it to fit and came up with a few Ideas that would work, but all required a fair bit of filler.

    Called into Rally Weld on my way home from work and came away with a new spoiler £67. Not cheap, but not that expensive when you consider how much these cars cost to build these days.

    Only down side is that it's going to take time and patience to fit as I've already matched it up to the front panel and it needs a fair bit of shaping.

    I've just read a few threads on forums and everyone agrees that the spoiler is a bit of a pig to fit, but you have to get it at the right height.
     
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