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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.
    Attached Images Attached Images

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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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    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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    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.

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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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    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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    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.

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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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    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.

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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

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

    You did well and as for the battle scars caused during the removal, not a concern as you will be rewearing in that area anyway. Good to get everything blasted and treated, that way you know it’s done

    As for the roof, go for it with a doner panel as you know they will fit. Again pain in tha as job but you will only do it once.

    Keep it going

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

    More time spent cutting out rust.
    IMG_2758.JPG

    IMG_2760.JPG

    And making repairs
    IMG_2761.JPG

    Primed the underside of the boot floor to.
    Last edited by Zakspak; 27-10-2018 at 19:50.

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

    Got on with repairs to the donor rear chassis rails so they are ready for fitting.

    IMG_2762.JPG

    Had to cut back further than the previous repair. On this section I've repaired as per the original section. Inner strengthener and main chassis rail. Had to do it in 4 main pieces because to the shape of the section.
    Started with the bottom of the strengthener, then its side, followed by the bottom of the rail and the side.
    Pic above before the bottom panel was put on. Used a piece of my old floor in the repair. Part of the original car in the donor chassis. The holes are to plug weld the inner section to the outer.


    All seam welded and finished off.

    IMG_2763.JPG

    At the front end I chopped out the corroded section opened up by blasting. The inner strengthener runs to this point. The rust formed between the 2 layers. Rather than repair the inner and outer sections separately, as its right at the end of the strengthener I've fitted a section of thicker steal, seam welded inside and out. Same on both (where the unpainted section is)

    IMG_2764.JPG

    At the back, the bottom section had deep pitting on the inside, so I've cut that out and replaced it.

    IMG_2765.JPG

    Still got to do the front ends where they slot under the middle sections
    IMG_2677.JPG

    There's 3 days of work in these last 2 posts.
    And just because there's not enough to do on my little project and I've got stacks of time I'm going for the roof replacement.
    The donor roof I mentioned earlier, was really nice, and is now sat in my garage. So it will be "good bye" to the sun roof.

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

    Update time. Been a couple of months, but got a fair bit done.
    finished off the donor chassis leg repairs, replacing the front end sections that were thin. I've used thicker plate on both as this will be one of my main jacking points. Can't use a standard ford jack (not sure I'd want to) with the X-Pack and side skirts.
    same repair both sides.
    IMG_2789.JPG

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

    Now with both donor rails ready, it's time to remove the original rails, one at a time.
    I'll try to explain as before step by step how I've done this job as a reference for anyone doing the same.

    First off I measured and marked as many points as I could think of that would be useful for fitting and aligning.
    I've got a copy of the dimensions drawing that is available from this and other sights. (more on that later)
    The front sections where held with bolts from where I'd made other floor repairs, so it was mainly the spot welds in the boot floor that were left that had to be removed.
    I started with the Left side (passenger side)

    IMG_2863.JPG

    The back end of the rail has a plate welded on it kind of like a cap, this is used for attaching the rear panel. (I've made up 2 replacements that I'll fit later when I do the rear panel). I cut the rear panel either side of this, cut the spot welds and folded the section back to gain better access to the rear rail flange. I didn't want to damage the strengthening plates inside the boot, so I drilled the rear most welds through the chassis flanges.
    With the Rail off I cleaned the surface up.

    you can see one of the repair patches by the damper opening I fitted previously from inside the car.

    IMG_2865.JPG

    Then a dry fit of the donor rail just to be sure nothing was too wonky. It fitted in fairly well.

    IMG_2867.JPG

  26. #103
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    The floor section along the attachment area was fairly poor. I knew the right hand side was going to need attention as it was blown through on the upper surface inside the boot.
    I made up a template of the bad area, then cut this floor section out from the rear flange forward as required. This is a fairly easy repair panel (in my case) as I only had to cutout the flat section.

    IMG_2869.JPG

    Cleaned and primed the underside of the strengthening bracket, made my repair panel, with holes drilled to plug weld from the underside to the strengthening bracket. Tacked, then seam welded it in. Dressing the welds when done.

    IMG_2871.JPG
    The hole through the front of the strengthening bracket is for a fixing bolt to hold and align the rail later.

    With the chassis rail removed there's little flex in the body with it on the spit. It's only noticeable around that strengthening bracket when the body is upside down.

  27. #104
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    With the repairs done to the boot floor section I spayed inside the rail and what will be the enclosed floor section gloss black, just to give added protection for the future.
    Chassis rail now ready for fitting.
    It was laid in position and clamped where possible (around the damper opening) and tapped into final position. I drilled holes for bolting it in making little adjustments as I went, and cross checking the dimensions. The bolts pull the rails and the floor together. When happy with the final position, I marked the rail against the floor, removed it and drilled holes in the floor for the plug welds. Access for welding and dressing off being easier from the floor than at the flanges.
    IMG_2872.JPG

  28. #105
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    With the LH side rear chassis rail fitted, I started the RH side. Exactly the same process. Although I had to redo the floor repair where it arches over the axle, and the patch at the rear extends further forward. Initially I tried to keep the raised square pressings, but the metal was so corroded/thin that in the end I just deleted them. I'll probably have my fuel pump etc in this area, so it may give me a little more location flexibility.

    IMG_2884.JPG

    You can see the underside of the floor is very pitted after cleaning.
    IMG_2886.JPG

    Small repair to the front of the boot panel where it joints the main floor panel. got a similar repair to do on the LH side but access will be easier when I do the LH inner wheel arch.
    IMG_2888.JPG

    Patch for the section that arches over the axle
    IMG_2895.JPG
    I'll weld a flange on to this for the inner arch when I do the inner arch.

    rear repair patch tacked in, with the square pressing still in place. Had a bit of extra work to do here as the metal was a bit thin at the rear left of the panel (around where the clamp is) and I had to make a little patch.
    IMG_2896.JPG

    Also had to extend the repair patch forward as again decided the metal was too thin. would have been nicer to do this in one big panel. Square pressings now deleted.
    IMG_2898.JPG

    Final fitting and welding as per the LH side.

    Both rails welded in and primed.
    IMG_3124.JPG

    Few notes :-
    Don't assume ford chassis rails are the same, something to consider if planning to replace just one. The donor rails front spring hanger are 5mm narrower than the ones I removed.
    I made lots of measured marks based on if they were correct at original then my replacements would be correct. That may not work.
    Refer to the dimension drawings, measure, dry fit and check multiple times. Even doing this my front spring hangers have ended up 3mm wider apart. Original dimension was exact. It's only 3mm but I'd rather be improving than not.
    If I did this again, I'd mark of centre datum's and work from them, rather than fit one rail and fit the other based of it. Finding the centre datum with the shell on a spit is fairly straight forward if the body sits level when up right as the spit must be well aligned with the body centre line.
    Should I have fitted a new boot floor ? Maybe. I think it would have been less work and given a better finish as per the main floor. But there's still the thing about trying to keep as much of the original car as possible and cost. Practically, I'd recommend a new boot floor.

  29. #106
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    On to the centre sections.
    New metal on to new metal. Nice !
    I welded extra plates in where the jacking point is to increase its strength, hopefully to stop it becoming dented when on stands or jacking.
    I over laid the new sections against the originals to check alignment, and marked them for drilling the plug weld holes.
    Again insides where painted with the gloss black. I marked where the originals where and removed them. Due to the replacement floor it was just a matter of un-bolting them. I had to cut through the front chassis rail just ahead of where the centre section extends.
    Again lots of measurements taken and marked off, although the dimension drawing doesn't show any critical dimensions here. Not as many pictures taken as I thought, so hope it makes sense.

    Did the RH side first just because I was set up for it from the rear section.
    IMG_3114.JPG
    IMG_3119.JPG

    Rail is bolted down first, for alignment and also to pull the rail and the floor together. That's the gap I had to close up.
    IMG_3120.JPG
    IMG_3121.JPG

    and bolted in place

    IMG_3122.JPG

    Plug welds made mainly from underneath through the flanges.

    Then the LH side.
    IMG_3118.JPG

    Complete

    IMG_3123.JPG

  30. #107
    Bodger

    My 1st Project
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Got my parts back from the media blasters. Bonnet looks so much better. It had so much paint on it the edges of the centre bulge had lost definition and looked more rounded.

    IMG_2936.JPG

    Found a little split from the door lock securing screw hole, its wasn't visible before. Straight forward repair.

    IMG_2932.JPG

    IMG_2933.JPG

    All primed for later use. I've still got to do some cleaning up inside the doors, boot and bonnet. The media blasters didn't want to chance damaging the skins.

    IMG_2940.JPG
    IMG_2938.JPG
    IMG_2939.JPG
    IMG_2942.JPG

    I've had a spare scuttle panel done to, that I'll probably use as it's the later screw on type, and will save me repairing the holes from the spot welds. I'm thinking of making both the heater bubble and scuttle panel removable with captive nuts for the bubble and screws for the scuttle.

  31. #108
    Spanner Monkey HOSSMAN's Avatar

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

    Will be a nice when done

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  33. #109
    Bodger

    My 1st Project
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    With the rails in place I've fitted spring skid plates and the chassis radius arm brackets.
    I'm using RIX engineering radius arms (tramp bars).
    The car doesn't really need the skid plates, being a road car, but they finish the front spring hangers off nicely.
    Despite the good reviews of the RIX radius arms, the chassis brackets seem to be a bit "one size fits all". I had to cut and re-weld the outer flanges so the inner one would contact the body. Also cut off the flange that wraps over the chassis rail. I left it off and welded along the edge of the side plate. See the pics. Fitting radius arm brackets has been covered on here before so I wont bother too much more detail.

    Holes cut for the captive bolt in the bracket.
    IMG_3163.JPG

    There's a lot of measuring and checking, before making small cuts until they are right.
    IMG_3165.JPG

    IMG_3166.JPG

    IMG_3168.JPG

    IMG_3169.JPG

    Dry fitting

    IMG_3164.JPG

    IMG_3170.JPG

    Final welding.

    IMG_3172.JPG

    IMG_3173.JPG

    IMG_3174.JPG

    IMG_3180.JPG

    IMG_3179.JPG

    IMG_E3178.JPG

    Job done. More or less. There's a few little bits to do on the rear chassis and boot floor, tidying up. Most of it will be done whilst doing other jobs.

    Next up the front end. Front chassis legs, inner wings, front panel. I'll be building a frame/jig for the front end to help keep every thing as it should be. Initial checks look like the front end is really tight on the tolerances.
    Chassis legs ordered today. I'll be using the Heavy duty legs from motor sport tools.
    Fingers crossed, with it all being new metal, there wont be any annoying repairs slowing progress down.

  34. #110
    Spanner Monkey

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

    She’s getting there and keep at it, hardest part done and flipin heck you have put some effort into it

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  36. #111
    Bodger

    My 1st Project
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks Donnie, it’s been a bit of a slog working out how to do stuff, hopefully the front end will go well without any drama or problems. Still loads to do still. Thanks for looking in. Cheers

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