Mk2 Escort Group 4 Rally Car

stuvy · Mar 27, 2013

under some filler of a vw i saw a few years back ther was a chunk of wood and some garden hose... dont ask!

the door bottoms look great mate, cant wait to see this finished

rallyreturn · Mar 27, 2013

stuvy said:
under some filler of a vw i saw a few years back ther was a chunk of wood and some garden hose... dont ask!

the door bottoms look great mate, cant wait to see this finished

Thanks Stuvy,

I hope both of us live long enough because it'll be quite a few years before this project turns a wheel

rallyreturn · Mar 27, 2013

Quarter panel now repaired as far as rot is concerned. Not as easy a repair as I first thought. The metal was so thin due to rot that the heat from the welder kept burning through. It's not as good as I was hoping but It'll look okay after It's shaped with filler.

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I got around to cutting off the blank for the petrol filler, made a new blank but run out of mig gas before I could tack it into place. Just got back with a new bottle so I'll finish it over the Bank Holiday.

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rallyreturn · Mar 29, 2013

Welded up and dressed the fuel filler blank. On close inspection I could see the quarter panel around this area was slightly warped, so I had to use more filler than I had hoped. Not quite finished, I'm writing this whilst waiting for the last skim of filler to dry.

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rallyreturn · Mar 30, 2013

As I have filled my garage with filler dust, decided to fill in the arch countersunk rivets, another 3 to go..!!!!

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rallyreturn · Mar 31, 2013

The boot seal rail needed repairs so got the welder and grinder out. I also started the filling on the other quarter panel and rear arch.

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rallyreturn · Apr 3, 2013

I wasn't happy with the amount of filler I used for the quarter panel fuel cap area, so off it came, there was more than I was expecting, just goes to show you don't notice how thick it gets when you build it up in stages, lesson learned..!!!! I spent more time to panel beat the warped panel, (not my best skill, but getting better). Much happier with it and so much less filler used.

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Cleaned up both boot wells where the patch panels that I fabricated were welded.

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turbom · Apr 4, 2013

A very nice build you are doing.Have you any bulkhead gussets fitted? as i couldn"t see any.

rallyreturn · Apr 4, 2013

turbom said:
A very nice build you are doing.Have you any bulkhead gussets fitted? as i couldn"t see any.

Yes they were fitted by the previous owner, not the best welding but I have dressed them with a multi tool grinder. I did think about replacing them with the exhaust recessed type but having already overpaid for the shell I need to use as many of the parts already fitted, not that there are many left..!!

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rallyreturn · Apr 4, 2013

Spent another full day on bodywork, the top of the Boot surround looks like a water trap and has pitted badly. Started by removing all the corrosion with a wire wheel brush and then used more filler to repair the surface.

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Moved onto the front end and welded up all the pin holes around the battery area of the inner wing, but the more I welded the bigger the holes became, ended up just being happy with a few pin holes. Finished off grinding to an exceptable repair and MORE filler, I also did a bit more panel beating on the top of the inner wing, this was one of my first repair panels that I welded 2 yrs ago. More filler to finish...!!!

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jpmillermatic · Apr 7, 2013

very nice work...!

JP

rallyreturn · Apr 12, 2013

Trial fitted the doors and made a few adjustments, including having to grind the weld off the bottom of one of the wings, pull it out 5mm and reweld into position. Shut lines are quite good but the final fit will be even better when I have a second pair of hands to help me.

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I've also spent Hours and Hours on the engine bay and front panel but it's almost ready for primer..!!

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Epicyclic · Apr 12, 2013

Looks well good! Bet you're chuffed to see it in one(ish) piece.
Keep the photos coming...

katbloke · Apr 13, 2013

Nice to see this beauty progressing, many moons ago I posted a link to another awesome mk2 build but the original link no longer works but have found its new version.

http://forum.wscc.co.uk/forum/index.php?/topic/45193-windys-new-project/

rallyreturn · Apr 14, 2013

katbloke said:
Nice to see this beauty progressing, many moons ago I posted a link to another awesome mk2 build but the original link no longer works but have found its new version.

http://forum.wscc.co.uk/forum/index.php?/topic/45193-windys-new-project/

Yes thank you for that original link, It's that build that has given me not only the inspiration but also the "how to do it"...!!!! :clapping:

rallyreturn · Apr 21, 2013

I've spent days sanding the floorpan from boot to bulkhead..!! as expected there were a few rusty areas and pin holes, so more welding. Got a tip from the internet and used white vinegar to convert the rust, worked a treat but you do have to rinse off with water to stop the acid in the vinegar eating away at the good metal. The worst area is in the front passenger footwell, badly pitted but not bad enough to justify a patch panel, I'll skim over the pitts with stopper just to make it look smoother when painted.

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I made a start on fitting the firewall panel today, but like all the other jobs centered around the previous owners work I had to make a bracket to get it to fit. Because the turret infills are different sizes I needed to lift up the firewall so that it ran parallel with the suspension box, only problem was the holes that I had already drilled along the bottom of the firewall now missed the middle area of the suspension box, then whilst trial fitting I noticed that the holes lined up exactly on the bend of the bracket. The only quick solution was to add some weld to fill up this part of the bracket and drill through the welds, not pretty but it works and won't be seen.

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I now have to make some extra infills to match the overhanging firewall at the turrets, cardboard templates already made, just need to transfer them to metal and weld into place.

Exuptoy · Apr 21, 2013

Nice work as usual. :clapping:

lazybones51 · Apr 22, 2013

Just read this thread from page one, your doing a fantastic job! Makes me want to get of my **** and sort my own car out :clapping:

jpmillermatic · Apr 22, 2013

beautiful work!...love the classic lines of those fenders....

JP

rallyreturn · Apr 22, 2013

Thanks all for the comments. It might be hard work but far more enjoyable than the work I do for a living..!!

Just waiting for some dry weather this week to take it to Rally Weld.

Mk2 Escort Group 4 Rally Car

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