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

  1. #81
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    I marked up the A pillars to show where the formed section at the front of the sill starts. The right side was the new sill I did before deciding to go with the full floor panel. The Left side I still had original metal under the the old sill repairs.
    And hung a door for alignment.
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  2. #82
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Fitting and alignment. To get the sill to sit in line with the bottom of the door I had a gap at the top of the door step (see pic) The door step then was in contact with the door frame. I dealt with this by slitting just below the top of the step for a length of about 15cm to allow it to meet the original metal. I wasn't 100% sure it would be unnoticeable, but its worked out fine, the step doesn't look like its got a hump.
    The sill was tacked at the top in various places but not along the top flange to floor. Once this was done a block of 3x2 wood a mallet was used along the bottom to knock the sill up to get the door gap as desired. Its surprising how fine you can make this adjustment.
    The annoying thing was, when I first offered the sill up and it didn't fit and I couldn't work out what to do, I'd called the guy who's going to do my paint and he'd told me to do just this. But as the gaps where so big I couldn't see how it would work. Hence the amount of wasted time. Thinking back I probably could have left the sill I put on before and knocked it in to shape. Never mind, the Left side was done in a couple of evening sessions.

    The masking tape along the sill was to help show how the gap was looking by giving a good contrast between the sill, gap and door. That was my idea and it worked out.
    Pic 4 you can see how bending that bottom edge in to make the sill more of a box section more or less removes the big gap I had between it and the floor.
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  3. #83
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    And the Left side, same as before. Bit more detail in the pics of where I sliced just below the step to help with alignment.
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  4. #84
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Next up Left side splash/kick panel. (both sides to do, but as I'm all set up on the left)
    To start with I had a full length wing rail repair from the previous owner. This was like so most, a running/MOT repair, not the most exacting work. I removed this just at the bulkhead end and the corroded kick panel. This revealed what I expected, the outer edge of the "Cowl top panel" (upper bulkhead) has gone. I did a bit of hunting and found a thread on here that a guy is running for a mk2 van rebuild. He's got a couple of nice pics of this area on his van that whilst rotted out you can still see the form really well and how the Fitch panel fits on with the cowl and the inner wing, wing support. So I used these pics with a few others I found to work out the repair.
    I also found a hole in the top of the bulkhead. You have 3 panels meeting at this point in a sandwich. Cowl Top, Bulkhead and inner wing.
    I had to carefully, so as not to further damage the bulkhead, cut back the inner wing flange so as to expose the bulkhead flange which is in the centre of this sandwich.
    Make up a small repair section for the Bulkhead. Then make the repair piece for the cowl top.
    I had a bit of head scratching again as cowl top panel has some complicated shapes up in that corner and previous repairs hid what was going on, so with my repair piece in I then realised I had to make a further small patch and remove what had been done before where the panel bends up toward the windscreen and around toward the door pillar.
    Now this is done, I'm ready to get on and fit the kick panel. (today's job, now I'm up to date here)
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  5. #85
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Kick panel update. Took a couple of days in the end but the LH side all done.
    IMG_2288.JPG

    Its the little extra jobs that slow things down, like removing and replacing the brackets and loom supports from the old panel
    IMG_2253.JPG

    I've plug welded where the spot welds were, but also stitch welded down the A pillar, along the floor join and at the top inside where the kick panel meets the bulkhead/cowl as per works strengthening guide I have. Its probably OTT but I'd rather not find out later that things weren't right. Along the front join to the bulkhead it's fully seam welded.
    I've also removed a section of the wheel bowl that was pot marked with rust and thin and replaced that.
    The Bowl area has also been beaten in around the outer area. You can see in previous pics in the thread, witness marks where the inner edge of the tyre made contact with the bowl on full lock. I'd taken a hammer to it before, but it was rough. It's now fairly smooth and uniform
    IMG_2294.JPG
    note about the top join, the kick panel top flange isn't very wide, so drilling and plug welding would have been a bit tricky.

    Welds all dressed and painted it's not too bad a job, but never quite as nice as I'd like. I'll be seam sealing at the end, so the rough edges should disappear.
    IMG_2295.JPG
    IMG_2299.JPG

  6. #86
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Right hand side splash/ kick panel. More or less the same as the LH side.
    IMG_2300.JPG

    IMG_2301.JPG

    This time I removed the old under seal first using a heat gun and scraper. Not as bad a job as I expected.
    As on the LH side the inner wing flange has been cut back to expose and allow bulkhead repair. It's a bit bigger on this side and more tricky to get into. (the rough bit up in the corner is the inner wing)
    IMG_2381.JPG

    IMG_2382.JPG


    I've got the same situation with old MOT repairs to the wing rail. Although when I removed all the old crap I found the bulkhead cowl whilst rotted, was still there so a great pattern to work to. Shame I didn't know about this when I did the other side. the panel repair I've done on the LH side is a bit narrow, but I don't think it makes any real odds to fitting the "wing rail gusset panel" later.
    IMG_2373.JPG

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

    So bulkhead repair made and old crap removed and cleaned up. I've cut back and replaced the A pillar front flange carrying the repair piece up in to the windscreen panel corner.
    IMG_2383.JPG

    IMG_2386.JPG

    Cut out the rot on the bulkhead cowl, make up and tack in the repair panel, before seam welding it with plug welds to the bulkhead flange

    IMG_2414.JPG

    IMG_2416.JPG

    I've left the old piece of wing rail gusset attached to the cowl as a guide for later. Also spent some time stripping back old paint and sorting out surface rust around and under the bonnet hinge brackets.

    And the kick panel attached. Its plug and tack welded for now until I'm back to finish it off. Going to have to make a repair to the wheel bowl again this side for the same reasons. Also got the strengthener / splash shield to fit. The inside bracket and loom supports all fitted and I've again started to panel beat the bowl to allow the wheel clearance.

    IMG_2415.JPG

    Bottom join, its tidier than the other side and little more like the original join lines.

    IMG_2418.JPG

    I've tried a new way of attaching pictures, so I hope my posts are a bit clearer. To be continued as other distractions (decorating, keeping the Mrs happy and work) allow.

  8. #88
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Looking good and doing well. Makes you smile when it finally takes shape. Keep the updates coming as they are great

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  10. #89
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Floor done ! Feels likes progress.

    IMG_2636.JPG

    IMG_2637.JPG

    Insert to replace corroded area, same as the other side

    IMG_2640.JPG

    and all painted

    IMG_2641.JPG

    IMG_2643.JPG

    IMG_2642.JPG

    hopfully the pics are the right way round. They look ok on a lap top but on phone they weren't

  11. #90
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Next up, chassis rails starting at the rear section. Plan is to do the drivers side first. I'll do the rear and centre section both sides, then I will drop the shell down on stands and do either the inner wings or front chassis sections. But as usual the plan has to stay flexible. Whilst the shell is upside down on the spit I'll do all the stitch welding on the floor pan underside and around the tunnel.

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

    That’s been a good fortnights work, keep it up and it will soon be done

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  14. #92
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks Donnie, the update time line is a bit off. I struggle to get consecutive days on the car and updates here have to take a back seat for when I’m away with work. That right hand side would probably have been 3-4 days all in if I could have a clear run.

    Got a few hours last night and have cleaned up the boot floor underside and scratched my head on how to actually move forward with the chassis rails. Been considering trying to remove the old ones in one piece so they can been cleaned up and repaired by someone after a set of cheap original rails rather than the pattern parts.
    There’s a fair bit of prep work to do before my rails come off and the replacements go on. The replacements need cleaning (media blasting is the plan) and a couple of repairs.

    Decided that the box section that sits across between the rear arches is going to come out first so I can check and clean up in there and get to the chassis spot welds under it. Then weld it back on. Once that’s done remove the replace rails, one at a time with my repaired ones to help ensure the body integrity.
    Enough talk for now, going to get out there and try and do a bit.

  15. #93
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Now that’s a task but once done will be good as you won’t have to worry about it for a long time. You only want to do it once so it’s worth taking the time to do it properly and the results so far have been spot on

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  17. #94
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Had a productive couple of afternoon sessions last week.

    Got the underside of the boot floor cleaned up. Was worried it would turn into a "tea bag" once I took the wire wheel to it.

    IMG_2663.JPG

    IMG_2666.JPG

    Then I've removed the rear shock reinforcement panel (box section). Made a bit of a mess of this causing some damage to the boot floor panel at several of the spot welds. Nothing serious, but will use up some time sorting out.

    IMG_2670.JPG

    Really glad I've done this as it's exposed the surface rust on the boot floor and allows me to get the box section cleaned up

    IMG_2671.JPG

    Next morning, removed a bodged repair from my spare chassis rail, stripped my other spare door and loaded the car up with more parts than I thought possible. And off to be media blasted.
    2 x doors, Bonnet, 2 x boot lids, heater bubble, Scuttle panel, 2 x rear chassis rails, Rear box section and 4 x seat rails.

  18. #95
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Well worth the effort Donnie, as you say it will be a right pain in the arse to do all the work and then have a problem with a hard to reach area later.
    Thanks for your comments.

    I had a moment of thinking of changing the boot floor panel. But the cars getting more like "Triggers broom" if I do that. Then there's the expense. Hopefully I wont regret doing repairs later rather than a complete panel change.

    I've also been batting the roof issue about for some time. I said at the start I was keeping the sun roof. I like it. But, what if in the future I want to do other things with the car? Changing the roof on a finished car will be agro. I've looked at a couple of panels but they have been no good, so I put the idea off. I've checked the "Higgins" option, but the guy I spoke to put me right off it. Now someone tells me they have a donor panel in good condition, so the roof change maybe back on.

  19. #96
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    The media blasters did me a good turn. They offered to do the chassis rails and box section whilst I waited !
    Rest I'll collect as and when.

    IMG_2675.JPG

    IMG_2681.JPG

    Close up of the rails. Few repairs needed, but I don't think it's anything too difficult.

    IMG_2677.JPG

    IMG_2679.JPG

  20. #97
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    And the bodged repair. Actually worse than I thought. The weld is full of holes. I cut out a box section that was welded in as a strengthener. Would have made more sense to make a proper repair.

    IMG_2678.JPG

    IMG_2680.JPG

    Got home and got it all primed.

    IMG_2682.JPG

    IMG_2683.JPG

    Last of all, I managed to get in and clean up the surface under the Box section before heading to work. Not as bad as I first looked.

    IMG_2684.JPG

    Next job is sort out the bits of damage I did, and make repairs to the chassis rails.

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