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Thread: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

  1. #401
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    1st of June, off to paint !!!

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    Lucky with the weather

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    Had a great driver, nothing rushed and a nice steady run despite the heavy traffic
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    Safe at the paint shop, Mk3 2.0L S Capri out in the sun.
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    And the moment of truth when the paint shop inspects your work. All good, apparently I've done ok
    After sometime talking over my car, 2hrs looking at the collection of cars in the shop at various stages. 2 Mk1 Capris, 3 Mk1 Escorts, a Sierra Cosworth 500 and 2.8i S Cortina

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Apologies for not wanting to go back through 11 pages, but what's your final choice of colour?
    Shell looking good :-)

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Looking forward to the next update and seeing some paint on her

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Great work on the car, the shell is looking really good. Can't wait to see it painted

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    No worries dt36 and thanks. I don't want to post old pics up here now as it could be a bit confusing, so Page 1 and scroll down 5 or 6 posts, and there's pics from 1992/93. So the White with Blue. Loosing the Ford logos and having a stylised racing "77" on the doors instead. That will be vinyl

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks gents for the comments and interest.
    Simon D, only just seen your build thread, lovely work, I thought at the start you'd put it back standard as a Harrier, but I guess it was to far down the line to go back. Love the pipe brackets, simple and effective

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Just because the car is at paint, there's still loads to do and I'm dropping behind on things.
    Preparing the head liner.
    We're going to put the glass in at the shop so I'm not doing it alone at home with the expensive very difficult to replace bronze tint glass I have. Back in the day I wouldn't have thought twice about doing it myself.

    Had this one in storage for 30 odd years, came up really well with a clean, just a few small marks.
    IMG_0526.JPG
    My original was knackered as well as having the sun roof hole cut in it.

    Roof bars out, wiped down with an foil scouring pad, etched and painted white
    Any one doing a head lining, note the bars are colour coded. Red on the left side (Port) and on the right 1. Blue (Front), 2. Brown, 3. Green, 4, Yellow (back)
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    This liner has cotton sleeves for the bars, later ones just have the liner stitching into tubes

    And spayed black to match the rest of the interior with vinyl paint.
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Door locks stripped.

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    Close up of the barrel parts. There's a small (2mm) rolled pin to knock out to get to the barrel. After that it's fairly straight forward
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    Mark the barrel so you don't forget to orientation. and take care with the leavers not to mix them up

    The leavers removed
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    The leavers sit on a fine spring under the small arm on the side. The springs are easily damaged when removing if they are stuck in with years of crap, or fall out if they are free.

    One of my locks was so full of old crud, dust, polish etc I had to tap the leavers out, and the key didn't work. Now the barrel springs back when you let go of the key. The fine springs and rolled pins are available

    I've read people saying you can move the leavers around to match a different key, that's not right, there are a lot of different leavers. It would be possible to make new leavers with a set of needle files and some care to match 2 odd locks to one key.

    The door handles are going to be media blasted and repainted black.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Split rim bolts.
    Did this some time back. 72 cone washers individually cleaned, checked and painted, and 72 bolts cut down, cut ends smoothed and painted. The bolts are cut down because I wanted to match the original shank & thread sections.
    Really need to get the wheels built up. I've used a metallic black for them which is similar to the anodised finish they had originally
    IMG_0650.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Visit to see the car and drop some bits off last week.

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    All the gaps finalised, which apparently didn't take long. I'm glad about that after all the time I spent on them. Some panel straightening done, such as a bow in the bottom of one door and an old dent in the other. Decided this was best left to the body shop so I didn't muck it up.

    IMG_0609.JPG
    Front end has had a coat of primer to show up surface blemishes

    Left hand rear arch getting a skim of filler for blending it in, and a skim over the door to.

    IMG_0610.JPG

    Be heading back next week to take the rear bumper and light clusters for final test fitting, and see progress.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Quote Originally Posted by Zakspak View Post
    Thanks gents for the comments and interest.
    Simon D, only just seen your build thread, lovely work, I thought at the start you'd put it back standard as a Harrier, but I guess it was to far down the line to go back. Love the pipe brackets, simple and effective
    I did think about trying to undo all the work that has been done but it's just too much work. Trying to undo all the crap work done by the last owner/company that did the work for him was enough work on its own

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Been a while again
    Door handles and Locks

    media blasted
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    Made new leaver stops
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    Original nylon ones had got brittle and snapped except for this one (I have spare door handles )

    New ones held in place with epoxy adhesive
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    Everything cleaned and painted. I wasn't happy with the wear on the barrel leavers and the keys, so I found a guy who can replace the leavers and cut new keys to match. Also new O rings, and rolled pins. Boot lock has had the same attention. Found the boot lock was a different code but so worn it always worked with the key. The locksmith has now matched it to the doors
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    All back together, using graphite in the barrels. even cleaned and painted the fixing screws Better than new
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    More part prep
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Steering column next Stripped and painted

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    I've fitter new top and bottom Nylon bushes. The bottom bush was not great. The top old roller bearing was ok, but thought for the cost I'd try the nylon top, and got to say I think it's worth it.

    Ignition barrel stripped, checked and cleaned. I'm replacing the cables with new.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Lots of parts prep
    IMG_0962.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Wiper mechanism strip, clean, paint and rebuild.

    IMG_0947.JPG

    There's an additional rubber washer that seals under the nylon washer This isn't shown in any of my manuals but I've never removed the wiper mechanism so maybe it's from early cars. I've made replacements as they were both a bit worn and one was split.
    IMG_0976.JPG
    I also got new wave washers and shim washers, but unfortunately the shims OD was slightly bigger than original so don't work, I've just cleaned up the originals and reused them

    Motor cleaned, old grease replaced and tested. Re greasing the motor gears is time well spent as the original grease had migrated to the casing leaving the gears dry. Spindles and ball joints put back together with a good coating of lithium grease
    Ready for refitting

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    Last edited by Zakspak; 23-08-2021 at 13:12.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Looking fine and you are right about fitting the glass, had my brother with me and it was still a pain in the ass

    Looking forward to seeing her in colour

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    HI Donnie, trust you've been getting some miles on your car
    Slight change of plan with putting the colour on so don't hold your breath. Should be up to date here soon.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Body shop progress Mid June
    Decided that the under bumper grills would be better to be removable
    Template from the car, a frame made, bonded with Tiger seal and rivnuts fitted

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    And fitted

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    Roof prep
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    More progress and the body prep is coming on Late June
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    This was a very scruffy old steel that I've had for years. Can't remember what car it came from but must have been used on my Mk1 when I was repairing and painting it due to the green paint on it. Had the tyre removed, blasted and powder coated to use as a spare (Trim wheel )

    Brake Res plate and bulkhead break pipe plate have been done in a bright silver. (white wouldn't match and black would look odd in the engine bay)

    IMG_0951.JPG
    The rim looks a bit bent in the picture for some reason, but it isn't.

    Rubber gaskets made for the plates
    IMG_0965.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Looking forward to seeing her in her final colour and smile when you have had a change of plan prior to putting some colour on it. She’s going to be a cracker

    As for mine, up and running but still not finished as I am still working the wiring issue and now decided to get a pro in, so only job after that is finish the interior and that’s her done. Would put some photos up but alas people can’t see them even although I can so you just keep the updates coming and keep us motivated

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Brake pipes cleaned and prepped for fitting, including painting the washers white

    IMG_E1035.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Steering rack.
    This is a heavy duty competition rack I fitted a year or so before the car came off the road in 93 so its done very low mileage, but of course the pinon seal has gone hard.
    All the main motor sport shops do a full overhaul kit which I don't need, but I managed to find a specialist steering rack company. They sorted me out the seal, gasket and new boots, really nice quality and cheaper than any of the usual suppliers. Having sent a few pics and given back ground info for the guy to ID the rack, turns out it was modified by his dad when he first set up on his own. The company now makes racks from new rather than converting originals.

    Light surface rust from years of sitting
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    Pinion seal and gasket to be replaced
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    Cleaning up
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    Plastic wrapped around the ends to keep crap out of the rack

    Cleaned, painted, old grease removed. New pinion seal fitted, packed with new lithium grease and boots fitted.
    IMG_E1048.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Underside has had a raptor type coating tinted white to match the body
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    End of July 21.
    Inside, engine bay and boot painted
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    End of July 21 Outside primer
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    That's actually the underside protection going on the lower fairing


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    Dash detailed and I'm really happy with how the replacement speaker grill looks

    IMG_1031.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Here's the change of plan. Car is coming home in primer, reason being the chances of it getting dinked during fitting out are fairly high, and fixing primer will be a lot easier than paint.

    2nd August. Really lucky with the weather on the run to and from the body shop. 1st Aug was wet and windy.

    IMG_0984.JPG

    Even in primer it got some looks on the back of the transport
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    Back home
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    No hanging about, had the fuel and brake lines fitted a couple of days later. Not much more progress as works picked up again, at last.
    Potentially it will be fitted out to the point of having it running, but without the glass and interior fitted, then head back for exterior paint.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Funnily enough I actually like the external 'satin' finish - I wonder what it would look like in 'whatever' body colour is eventually sprayed?

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Great write up and a great project, looking forward to see it all painted and finished. Did you buy your kit from fibresport back then? I know they still make it but i think they only do the one piece front and the ford logos are gone, not sure though

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    I can understand the change of plan as it’s a mare worrying about the paint while you rebuild the car, now you can dress her and not worry. Speaker grill looks spot on

    Keep it coming

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks Kal, yes it’s an original Fibre Sport kit with the “Ford” stamps, it came via a motor sport shop which no longer exists (name escapes me now but I have an original advert in my collection of stuff).
    This time I’ve had a couple of opportunities to sit down with Steve Foster of Fibre Sport and talk about his time working with Ford Motor Sport on the various Mk1 and 2 Escort and Capri projects he was involved with. Very interesting guy. He also sorted me out with copies of the original fitting instructions the Ford Dealers had and the Fibre Sport version (which is better) and gave me additional advice on fitting. Done right he told me they used to lift shells with a guy on each arch and never had a failure.
    I didn’t think they had any of the X-pack moulds left after the fire in 2001, but I maybe wrong.
    Is that a BDA in your Mk1 ?

    Katana, I know what you mean about the satin finish, but I’m a bit old skool so it will be gloss.

    Donnie, will do. Hopefully I’ll get some garage time over the weekend, work allowing ��
    Last edited by Zakspak; 02-09-2021 at 22:33.

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  48. #433
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Quote Originally Posted by Zakspak View Post
    Thanks Kal, yes it’s an original Fibre Sport kit with the “Ford” stamps, it came via a motor sport shop which no longer exists (name escapes me now but I have an original advert in my collection of stuff).
    This time I’ve had a couple of opportunities to sit down with Steve Foster of Fibre Sport and talk about his time working with Ford Motor Sport on the various Mk1 and 2 Escort and Capri projects he was involved with. Very interesting guy. He also sorted me out with copies of the original fitting instructions the Ford Dealers had and the Fibre Sport version (which is better) and gave me additional advice on fitting. Done right he told me they used to lift shells with a guy on each arch and never had a failure.
    I didn’t think they had any of the X-pack moulds left after the fire in 2001, but I maybe wrong.
    Is that a BDA in your Mk1 ?

    Katana, I know what you mean about the satin finish, but I’m a bit old skool so it will be gloss.

    Donnie, will do. Hopefully I’ll get some garage time over the weekend, work allowing ��
    Yes mate, bda, was my all original rs1600, unfortunately i sold it some years ago

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Bummer Kal, sorry can't think of a silver lining there

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Ignition barrel back together and refitted to the column.
    Removed checked, cleaned and re-soldered the cables

    IMG_E1168.JPG

    IMG_E1175.JPG

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Fitted new long studs to the hubs.
    These have been cut down and the ends hand finished so the closed wheel nuts I'm using fit. The only issue with these studs is the shank is longer than the standard studs so my steel trim wheel is going to need a spacer behind it.

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Finally got the wheels together

    IMG_E1180.JPG

    IMG_1181.JPG

    The sealant is a high modulus natural cure silicone. The fast cure silicones use a chemical that can attack the alloy
    I also made up new O-rings although they aren't really necessary.

    IMG_E0146.JPG

    IMG_1182.JPG

    Bit fiddly and time consuming due to the tightening sequence, but happy with how they look. Plan is to get them ceramic coated.
    Last edited by Zakspak; 20-09-2021 at 23:40.

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  54. #438
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Loving the wheels :-)

  55. #439
    Mechanic

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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Quote Originally Posted by donnie View Post
    Loving the wheels :-)
    Thanks Donnie, me to.
    Got to find some nice tyres now.
    Unfortunately when I went to move them out the garage, back to storage I noticed that 2 weren’t right. It’s very subtle but the centre of the hub is different between the 8” & 9” wheels.
    When I stripped them everything was marked up even where they aligned (not really necessary but I did that anyway). However the guy I took them to then removed all the markers and didn’t make any notes or remark despite me telling him not to mix them up. It doesn’t make any real odds as they have been stripped cleaned, polished and coated, but when I put them back together last week I matched to what seemed best fit and didn’t notice that slight difference in the centre casting.
    Hey ho, last night I took the 2 apart, just the outer rims removed and swapped, and reassembled, but a good couple of hours to re-do them. Although it did prove the sealant had fully penetrated the join and made a good bond to the alloy.

  56. #440
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Not achieved much except drilling the wings rails for fixings and fixing a poor decision
    Around 1991 I removed the wiring loom supports in the engine bay because they're ugly and didn't allow flexibility.
    During this rebuild not only did I leave them in, I added 2 that would have been fitted originally.
    Some sort of brain fart. Now it's painted they are clearly still ugly and need to go.

    IMG_1259.JPG

    Lots of masking before drilling them off and grinding smooth with the Dremel.
    IMG_1260.JPG

    Zinc primer airbrushed on
    IMG_1265.JPG

    Fine filler, 2k primer and a good bit of time on the preparation
    IMG_1359.JPG

    Done
    IMG_1362.JPG

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