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

  1. #161
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Wing gusset plate.
    On the RH side I had part of the original flange that was spot welded to the bulk head, that was a good guide to placement. I marked it up, ground it off and clipped on the new one. Then clipped the wing on to line up as best as possible with the top of the scuttle panel/roof pillar. Then adjusted the gusset plate to meet the wing flange. Removed the wing.
    A plug weld at the bulkhead and wing rail to hold it in place, then a bit of hammer work to get it to form along the bottom flange before finishing off the plug welds. Same on the LH side, none of the original part was left there, but lining up to the wing is what's important.

    RH side plate
    IMG_4803.JPG
    IMG_4801.JPG

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

    Done a couple of other jobs away from the shell.
    Had the wheels stripped. They are back with me for various reasons I wont waste time on here. The centre disc and rear rim will be going for cleaning, powder coating at some point. I'm going to clean up and polish the front rim and rebuild them. I've spoken to a company that specialise in the older Compamotive wheels that are out of production with regard to re-building them. More to follow when I get on to them properly.

    IMG_4059.JPG

    IMG_4679.JPG

    Also stripped down the front struts, to check condition of the inserts and prep/paint the legs.
    Plan was to use the original inserts for now getting the car on the road and seeing how it goes. However it seems you can't get overhaul kits for them, so I'll be replacing the inserts with one of the performance parts available, but not decided what yet.

    That's how the struts look stripped

    IMG_4698.JPG

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

    Off the stands and back on to the skate. I took it out to strip off the paint around the roof panel joins, clean it down and blow off the dust from all the work so far.

    IMG_4701.JPG
    IMG_4702.JPG
    IMG_4706.JPG

  4. #164
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    On to the roof :-
    This is the last major body panel.
    Last look at that sun roof hole
    IMG_4745.JPG
    IMG_4746.JPG

  5. #165
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Roof panel joints stripped back.

    IMG_4703.JPG

    IMG_4704.JPG

    IMG_4705.JPG

    IMG_4747.JPG

    The black marks on the gutter are where the spot welds are. There's a lot of them 20-25mm (1") apart.
    There was also a lot of lead around the joints. I took this off with a course wire disc so it didn't kick up fine dust. Breathing mask is a must, and the reason I did this out side
    Last edited by Zakspak; 17-06-2019 at 14:56.

  6. #166
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Next I ground back the spot welds along the front and rear wind screen flanges, and pillars opening up these joints. I didn't use the spot weld drill as I wanted to avoid damage to the frame flange. The roof panel is scrap.

    IMG_4748.JPG

    Then I ran a 1mm cutting disc down the roof panel where the flange is formed. This released the panel leaving just the flange spot welded on to the gutter part of the frame to remove.

    I started off grinding the spot welds, but this didn't work so well as even with the roof panel gone the gap between the gutter outer edge and the frame is tight. So I went to the 6mm spot weld drill, taking my time on each weld and using a fine sharp chisel to split the drilled spots. It took about 3 hours to do both sides.
    Once again Ford's original production was not at it's best. about 1/2 the spot welds on the RH just popped apart with no effort, not really leaving any mark were they had been. Interesting how the Rh side of this shell has had various issues like this through out the rebuild.

    IMG_4751.JPG

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

    With the roof all gone, I found I'd gone a little deep with the 1mm cutter and had caught the frame, so a weld repair needed, and dressed back

    IMG_4778.JPG

    IMG_4779.JPG

    Frame then cleaned down and some surface rust dealt with before priming

    IMG_4782.JPG

    And that's me up to date.
    This week I'll be getting on with separating the donor roof panel from its frame when I'm home. I'm expecting it to take some time to do because its can't be rushed to avoid damage.
    The donor panel is really nice, does't seem to be a spot of filler on it. And look at the difference in the original production joints.

    Original panel front pillar join (lead removed)
    IMG_57033.JPG

    Donor panel front pillar join. No lead, no filler.
    IMG_4783.JPG

  8. #168
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Great stuff mate. keep up the great work

    Cheers

    Matt

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

    Thanks Matt, I’m trying but the rain has stopped play as I need to get the donor roof outside to start removing it from the frame. Just a bit too tight on space in the garage at the mo.
    Thanks for looking in and your comment.
    Cheers

  11. #170
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Great work to an excellent standard

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

    Quick update. Been working on removing the donor roof panel and as expected it's taking some time.
    First off I cleaned up all the seams to expose the spot welds.

    IMG_4814.JPG

    IMG_4815.JPG

    IMG_4816.JPG

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

    Because the roof panel has only a little more rigidity than a wet news paper I pre drilled it for the plug welding.
    Trying to centre punch and drill the flanges without the frame would be a trial with a risk of damage.

    IMG_4817.JPG

    IMG_4819.JPG

    Got this stamping on the front flange. Found similar at the rear of the boot floor.
    Also note the triangle cut out. There's one front and back and mark the centre line
    IMG_4818.JPG

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

    Getting the panel off the frame has to be done bit by bit cutting away the frame. I started by removing the side frame sections. This is made up of several sections forming a box section.
    I've got the roof on padded trestles to reduce the chance of damage/denting of the panel.

    IMG_4822.JPG

    IMG_4821.JPG

    Front and rear box sections are fairly easy, running a cutting disc along the back of the flange which leave just the flange attached to the roof panel. I pre drilled through the spot welds, so a sharp fine chisel separated the flanges.
    IMG_4826.JPG

    Corners are slow work needing several careful cuts followed by grinding back the part that is spot welded and brazed.
    IMG_4827.JPG

    IMG_4828.JPG

    Still got the side flanges along the gutters to remove. There's a lot of spot welds here, one every 20-25mm. Managed to make a start on this today, just about 10cm. Hope to get back on it later in the week.

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

    Dropped in to Burtons during the week, to size/check some new inserts for my front legs.
    Probably going to go with a set of the short Gaz top adjustable inserts.

    Also picked up a few things, full set of Super flex bushes for the back end, front hub bearing kits and a Grp4 Fabrications Pan hard rod kit and a Greyston long wheel stud. Only got one just to try it. I had a set from another supplier (not Greyston's) but they turned out to be 0.4mm too wide, not much but solid steel into solid steel it might as well of been 4mm. The Greyston stud fits fine, so I'll order a full set.

    IMG_4813.JPG

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

    Been there, done that!

    Last edited by Matt75; 24-06-2019 at 01:55.

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

    Matt, how did you get on with plug welding the gutter seams ? or did you use a spot welder ?
    That’s some roll cage you have fitted !
    Cheers

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

    Hey Mate,

    We just used the mig to plug weld and dressed it back then ran a big bead of sikaflex down the channel to smooth it out. Its a race car so show car finish isn't required

    Yes, we used about 30 meters of tubing!!

    Cheers

    Matt

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  21. #178
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    She’s coming in well, keep at it

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

    Just been looking at your build Donnie, really nice work. Interesting situation with the Retro Ford Radiator. I’ll have to check they’ve fixed that before I order mine.

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

    Took another 3+ hours to get the last of the frame off the roof panel so I could do a trial fit.
    Needed tapping down along the gutter panel using a thin piece of wood. The front pillar flange of the donor roof panel has a slightly different profile to my front pillars, the panel being a little wider, other than that its a straight fit.

    IMG_4834.JPG

    IMG_4835.JPG

    IMG_4836.JPG

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

    Back off, and cleaned up with a stripping disc and emery cloth before rubbing it over with some surface rust treatment using a scouring pad just to be belt and braces.

    IMG_4833.JPG

    Then a coat of zinc primer and a top coat of white in the closed areas. Masked the mating edges up as the 2k just makes cleaning up for welding more tricky and it scorches which doesn't look good.

    IMG_5038.JPG

    Blown into the cavity and outer of the frame with gloss black from a rattle can to seal the zinc primer, and white 2k on the areas that will be visible even though they'll be hidden behind the roof liner. Gutter, front and rear joins masked before applying the 2k white, then the weld points all pre cleaned.

    IMG_5039.JPG

    IMG_5040.JPG
    The string visible tied off by the front LH pillar is to pull the interior light loom through later.

    IMG_5041.JPG

    And the roof cross member.
    IMG_5042.JPG

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

    All the prep done and final dry fitting. Clamps laid out ready.

    IMG_5043.JPG
    The strap was an idea for holding the panel down tight as I didn't think I had enough clamps, but wasn't needed.

    Alignment checked I put in some blocks to lift the panel clear so I could run in the seam sealer. A second pair of hands would have been useful now and saved the use of the blocks.
    IMG_5044.JPG

    In place and clamped for welding. I tried to run the seam sealer in so it wouldn't get into the mating faces, but of course that wasn't 100% successful which effected how well those points plug welds laid in.
    Had a late night on this last Thursday, as I wanted to get the 4 corners done. Actually got more done than expected. The front and rear flanges went well. The gutter flanges are more tricky due to the limited space, but was not as bad as expected.
    The rear LH pillar plug welds could be better, this is due to the seam sealer getting around them. I clean it out so there's none visible but I think what's left that I can't get to burns and it soots up the cleaned area just enough

    IMG_5046.JPG

    Not complete as it got too late. This is after I finished with a lot of the clamps removed. Hopefully i'll get on it at the end of the week when I'm back from work. Maybe a good day on it and the welding will be done and possibly ground and dressed.

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

    great stuff, its a real ball ache doing this but it's come up well

    Cheers

    Matt

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  29. #184
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Sort of makes you appreciate the method sequence's used in new car production that are designed for sealing and the old one that weren't! I guess it was a case of weld it together and if you could brush sealant on the joint it got it - maybe!

  30. #185
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Hi Katana, you’re right.
    Modern production would probably not weld the roof, but use a polyurethaning sealing adhesive. I looked into doing just that, but having discussed it with people that know decided it best to stick with the original welded method as it’s a road car. Original build quality was not great, as I’ve noted previously, the tunnel was not square and they must of had a predetermined amount of sealer to use as it didn’t fill the gap, so the water crept in over the 15 years it was on the road previously, leading to excessive corrosion down the RH side. Although dimensions wise the tolerances of my car were spot on. Once all the welding is done I’ll be going around with the seem sealer.

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

    What a cracking job, feels good after the metal work is done. You must be looking forward to getting her into paint.

    Cracking job and keep coming with the updates says the man who never touched his for over a year

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  33. #187
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks again Donnie, you're not wrong about getting to paint, really want to try and hit my November target for that.
    And another update is here whist I'm in your part of the world working this weekend.

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    Re: 1977 Mk2 X-Pack Escort. Rebuilding my pride and joy.

    Little update. Roof finished. Few hours to finish the plug welding and another 3-4hrs dressing back the welds before the usual zinc paint. I put a series of "spot" welds around the panel pillar joins where it was originally brazed, just to stop the otherwise loose edges causing cracks in the finishing filler when its back on the road.

    IMG_5106.JPG

    IMG_5107.JPG

    When it's back down off the stands I'll push it outside seam seal the gutters and strip the roof back to remove the old vinyl roof glue.

  35. #189
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    As the shell is up on the stands and levelled I decided it was worth dealing the rear axle, radius arm and pan hard rod fitting before dropping it back onto the skate and then the spit .
    I've given all the rear axle parts a clean up, later they'll be going for media blasting.
    Fitted the poly bushes, even if they weren't an improvement on the rubber bushes, they look good.
    IMG_5104.JPG

    Had the bushes for the radius arms pressed in at a local garage to save knocking them in and possibly damaging the powder coat. They're fitted, and a very tight fit.
    IMG_5108.JPG


    All laid out ready. hoping to get it all fitted on Monday.
    I'd like to get the radius arm brackets tacked onto the axle to, time allowing.
    IMG_5109.JPG
    IMG_5110.JPG

  36. #190
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Some good motivation to see some more bits being trial fitted, installed

    Great job with the roof as it’s one job I have never tried

    Keep the updates coming

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

    Update time again. Had other stuff on so more time has passed than I'd hoped, and a bit of messing about needed with the pan hard rod fitting.
    First off cut off the ARB brackets, and clean up the axle where the brackets will go.
    IMG_5122.JPG

    IMG_5123.JPG

    Then fit the axle and check alignment. It all lined up nicely and was square which was good to know after all the work fitting the rear chassis rails. The rear of the car is supported on stands under the axle, and I've weighted the shell at the back to simulate its road weight on wheels, followed by bouncing it over a couple of days to help settle the suspension.

    IMG_5127.JPG

    Then fit and tack the axle radius arm brackets. That was fairly straight forward. I changed the mig wire over to 0.8mm for this.
    Again please to find the brackets fit slightly forward of top dead centre as they should.
    IMG_5128.JPG

    IMG_5129.JPG

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

    next the pan hard. this is the Grp4 fabrication kit for a left hand fitting exhaust. meaning the chassis bracket fits on the RH side, which is why the bracket is marked LH, for the exhaust not the bracket.
    Over all it's nicely made and having read up that's why I went with it. But like the Rix radius arms it still needed a fair amount of messing about and re-working

    IMG_5138.JPG

    the flat plate on the left is a floor strengthener to prevent cracking of the boot floor

    IMG_5139.JPG

    Bit of trimming and shaping to get the chassis bracket in place. but look at the out board face... Clearly it needs to be vertical. and overall profile isn't great.
    IMG_5146.JPG

    But there's more. I wanted to fit the axle bracket between the spring U bolts. I didn't want it to straddle one of the U bolts, and i wanted the minimum amount of thread extension at the ball joint to prevent a weak point.
    The problem is fitting the brackets as they come and in this manner can't be done.

    IMG_5144.JPG
    The black mark on the axle bracket is where the end of the rod lines up with the unmodified chassis bracket in place

    and the chassis bracket .....
    IMG_5147.JPG

    Bugger !!
    I made the decision to modify the chassis bracket, it already needed a fair amount of cutting about. .....

  39. #193
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    so I've cut the profiled section off the chassis mount, mounted the rod both ends having tacked the axle bracket, then marked the chassis and boot floor for profiling

    IMG_5145.JPG
    IMG_5153.JPG

    Used steel wire to get an accurate profile, which is transferred to light card,
    IMG_5155.JPG

    Light card checked and adjusted, and when correct the template transferred to a heavier card that also is similar thickness to the metal plate being used
    Light card
    IMG_5161.JPG

    Final template
    IMG_5162.JPG

    All fitted up and checked
    IMG_5234.JPG

    Transferred to 2.5 steel plate
    IMG_5163.JPG

    Cut out,trimmed, hand finished by file and test fitted. Both plates fit so well they hold in place unsupported
    IMG_5232.JPG

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

    Tacked and fully welded inside and fitment check.
    IMG_5273.JPG

    I've tried to get the rod as horizontal and parallel to the axle as possible. It runs very close to the hand break bar support. So I'll remove that and lower it by 10mm which should give the clearance without effecting the hand break.

    IMG_5235.JPG
    IMG_5236.JPG

    Final welding, dressing and shaping of the chassis bracket
    IMG_5274.JPG
    IMG_5275.JPG
    IMG_5276.JPG
    IMG_5277.JPG

    Finally tacked on to the shell
    IMG_5278.JPG

    IMG_5283.JPG

    IMG_5285.JPG

  41. #195
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Before taking the axle and springs off I removed the half shafts. They're held nice a firm on the car, far more so than on the bench. As the cars stood for 25/26 years, I figured the bearing maybe a bit tight, so rather than using a slide hammer, I used a combination of nuts and bolts to pull them out. RH side needed a bit more muscle, but both popped out ok with no twatting with big hammers.

    RH side
    IMG_5288.JPG

    IMG_5289.JPG

  42. #196
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    With the axle stripped and every thing ready, final welding of the brackets, moving the hand break guide and fitting new break pipe supports. Original pipping goes along the bottom of the axle, but running the pipes along the top make more sense and clears all the new brackets

    IMG_5290.JPG

    IMG_5291.JPG

    IMG_5292.JPG

    IMG_5293.JPG

    IMG_5294.JPG

    IMG_5295.JPG

    Off to media blasting next for the axle along with a pile of other bits

  43. #197
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    back down on the skate and outside with the new roof whist the garage gets a sweep out. Next up is back on the spit for fitting the rear outer tubs and finishing off some welds on the front chassis to floor. Little corrosion repair to do on the RH C pillar to.
    IMG_5296.JPG

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

    Got to smile and say the car was out this year :-)

    Coming on nicely and the towers took some doing

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


    Donnie, get an update on yours, you seem so close to being finished

  46. #200
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Tackled the "C" pillar repair this week.

    IMG_5302.JPG
    This "little" area of corrosion showed it's self in 1993 with a couple of tiny paint bubbles. As the car was off the road for the planned winter works I'd stripped it back and put some rust treatment on it. Not sure that really made any difference. This is "iceberg" rust..... the little bit you see on the surface is nothing to what's beneath.

    Clearly going to have to cut back further. I cut the sections out in such a way they could be put back and welded along lines that would be easily dressed back.
    IMG_5304.JPG

    Cleaned and Patched up the inner panel. There's a lot of surface rust inside the pillar to that needs cleaning back.
    IMG_5306.JPG


    Cleaned the back of this section and welded back in.
    IMG_5313.JPG

    Then the repair sections to replace the sections that were too far gone.
    IMG_5315.JPG

    The tricky bit here is getting the shape of the window pressing right.. I took this pic of the other side and used it as I worked out how the panels needed shaping. I also used a black marker to High light the lines.
    IMG_5314.JPG

    Done and dressed back. The pic doesn't show the profile that well, but it's there. I have deliberately left it a bit lower than it should be as the area will need a skim of filler on it and it will be easier to build up that shape than if I'd made it too pronounced
    IMG_5316.JPG

    IMG_5317.JPG

    I've cleaned up the inside of the pillar, underside of the window frame and boot opening, given it all rust treatment. When that's had a good 24hrs drying time I'll be praying the zinc primer up in there. This is all easily accessed through the rear wheel tub with the shell on the spit. Much easier than getting in the boot space upside down at a later date.

    The other side isn't as bad but needs cleaning up inside and rust treatment, I'll be on that next.
    Both sides will need seam sealing to stop water coming into the rear quarter from the louvred section. Ford did this in production by putting the sealer around that inner panel before fitting the outer quarter. But the way it was done leaves a trough between the panels which didn't get any paint on it, so is a prefect rust trap. It's going to be tricky getting the seam sealer in through the openings on the C pillar, but I'll find a way.

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