my mk5 cortina estate

Nashy · Jan 12, 2013

Will it be finished for 'Cortina Day' this year?
I'd love to see it in person.

Aaron.

Nashy · Jan 12, 2013

I've got to try and sort.out this …

On my mk5 Cortina Estate.
I have managed to 'pull' most of it out, back into shape, not quite finished yet though.
The end of the front panel will have to be replaced … I'm going to have a go at fabricating the piece needed myself, if it comes out Cra...err - rubbish (swear filter, I almost forgot. Lol), I'll get someone who has experience to do it for me, but I have to try or I'll never learn/know if I can do it.
It should be a 'walk in the park' compared to some of your fabrication work.

Aaron.

ian f · Jan 12, 2013

good luck

ian f · Feb 2, 2013

hi, hope everybody is well :waving:

so despite being in severe pain with sciatica i decided enough was enough and finally welded the scuttle panel in place :welder:

six pieces had to be made to make the panel usable. tacked in

and welded

ian f · Feb 2, 2013

after welding and grinding painted with bonda primer for protection until the respray

zx9 · Feb 2, 2013

Sciatica,

not conducive to working on cars especially this time of the year. Still doing fabulous work, I am really enjoying following your progress.

ian f · Feb 10, 2013

did abit more yesterday, bonnet hinge mounting

rot cut out

repair panel made

tacked in

and fully welded and ground down :welder:

still suffering with sciatica but will keep going :welder:

Nashy · Feb 10, 2013

I'm still struggling to get my welder set-up properly, so that I can weld my Cortina up.
Great work on yours though - I take my hat off to you.
Keep up the good work.
CheeRS,
Aaron.

ian f · Feb 23, 2013

hi, managed to weld the bonnet hinge mount back in place today. clamped up

cleaned the edges for welding

welded the lower edge as it was originally

just need to grind the plug welds back now

jpmillermatic · Feb 25, 2013

good progress!

JP

ian f · May 18, 2013

hi all

been having trouble with my welder lately (sip

) but seems back to normal now thanks to a new relay on the pcb did some test runs to confirm :welder:

so back on the car chassis rail under the brake servo

made the new piece to enable butt welding

and welded

and roughly ground back will finish the grinding when i paint the engine bay. thanks for looking :waving:

marlinspike · May 19, 2013

Great work, Ian. Very inspiring. Looking forward to more updates. I have loads to fo on my car, but fibd ut hard ti get motivated when it's cold and wet outside.

ian f · May 19, 2013

nice weather today with not much wind so decided to repair the rot behind the heater box

trimmed a patch for butt welding

and painted the inside

then lined up and a few tack welds added while adjustments were made

then fully welded a bit at a time to avoid too much heat buildup

then ground back roughly just enough to paint it as the neighbours and their kids were in the garden and didn't want to disturb them too much

followed by a coat of bondaprimer to hold it 'til the respray :welder:

marlinspike · May 19, 2013

That is some very impressive welding and fabrication, Ian. I am having trouble getting motivated to work on my car, but your thread inspires me to get stuck in.

ian f · May 19, 2013

cheers mate, makes it all worthwhile if it motivates someone else, i've seen threads on here that inspire me so it's good to give something back :welder:

jpmillermatic · May 20, 2013

glad your still plugging away on this project...looks great!

JP

ian f · May 25, 2013

nice weather today so done a bit more,panel below drivers side rear window

got a sheet of 48"x6"x1/2" 1mm steel i like this because i have 1 less fold to do (i'm that lazy!)

made a template

did the first bend

check against template

then hammered in the bottom fold

checking for fit

hammering in the tabs

another test fit

front edge formed

not too bad, shame it wont be seen

mike 109444 · May 25, 2013

"shame it won't be seen" Yes BUT you know it's there

rustyoldford · Jun 4, 2013

Top work there i do love fords, your work is inspirational.
Bet that its very difficult to get hold of any panels for your car these days i may start stocking up on sierra panels now as their cheap lol after seeing how much cortina stuff goes for !

Rustyoldford