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

  1. #201
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Got the pan hard rod turret finished off.
    IMG_5307.JPG

    Added a strengthening plate. The one attached from manufacture was nonsense, was too thick and couldn't be formed over the ribs in the boot floor

    IMG_5308.JPG

    IMG_5311.JPG

    IMG_5312.JPG

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

    Many thanks for posting these photos mate, just about to go in the garage to do the same ( tramp and panhard rod) to my MK2

    Your photos have helped

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

    No problem at all prox, that's exactly why I'm trying to put as much detail as possible, and the time spent doing it is worth it when I get a reply like yours. Hope your job has gone well.

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

    Great work!

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

    Great workmanship!

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

    very nice project you took up and learned in years. However, about the welds; needs more penetration. A lot of them looks to "cold" welded in previous posts.

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

    thats been 2 years ago, from what i saw. latest looking much better

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

    Hi gid, can you be more specific re the welds ? I make a point of checking for appropriate penetration of the welds. If any of them are a problem, then I would need to fix it now. I learnt welding many years ago and haven't done any for a long time before getting back on to my Escort. So I'm no expert.

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

    when the weld sits on top of the work you need to either turn the amps up a bit or the wire speed down a bit

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  14. #210
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Well it's been a month of little activity due to work and holidays.
    Got back on it last week although with some jet lag and struggled with motivation for several days, but I've worked through that.
    I've made a start on the rear inner arch tub extensions. This is the last major welding job I believe.
    I started by making a cardboard insert to line up the inner tub with the inside of the quarter panel so it could be marked for trimming back. 2 handed job which the Mrs helped with.
    Initial trimming
    IMG_6389.JPG
    The mismatch cutout on the RH side is from the original fitting, that will need an insert.
    Lots of double checking here. I had a strip of 0.75 sheet steel that's been very useful for checking alignment.

    With the initial trimming done, I fitted the rear x-pack to make templates. I want to make the extension meet the inside of the outer arch.
    Lots of bits of cardboard, pens and trimmings, it's like play school

    IMG_6390.JPG

    IMG_6392.JPG
    IMG_6393.JPG
    IMG_6395.JPG

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

    steel sheet marked up from the templates.
    IMG_6404.JPG

    All the double checking paid off, as a last check showed the initial straight sided panel would need a kink at the front inner edge. When fitted there must be a little twist.
    I'm making the extension up in two halves that will join at the top. 2 main reasons, ease of manufacture and fitting.

    Initial fitting of front half
    IMG_6405.JPG
    IMG_6406.JPG

    Rear half fitted, checking alignment
    IMG_6407.JPG
    IMG_6408.JPG

    Just the outer profile to trim. The top join is done with a step (Joggled) in the front piece.
    IMG_6409.JPG
    IMG_6414.JPG
    IMG_6416.JPG

    No time now for another week. I've made up templates for the other side as an initial guide so hopefully it wont take as long to sort out.

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

    Garage time has been very limited, but I've got the RH side tubs marked, cut and dry fitted last week.

    IMG_6441.JPG

    IMG_6445.JPG

    I've also made up the inserts for the sections of the Quarter panel that needed the filler pieces.
    Next job when home will be to remove the outer tubs both sides, fit the x-pack arches and measure off to trim the tubs to fit, then get on with the welding.
    Hopefully this coming week will be more productive, as my November schedule to have the engine, gear box etc dry fitted, the rear x-pack back on and the front wings fitted has well and truly slipped away.

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

    Good progress and a busy November schedule, looking forward to seeing the progress and you must smile when you see it taking shape as it will be worth it

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

    Hi donnie, had a bit of a smile on the last few days, had a busy week and made some good progress !

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

    Rear tubs done.

    Inserts ready, cleaned and ready for zinc primer
    IMG_6530.JPG

    I've filled the original fixing holes just to start fresh with alignment when I re fit them.
    IMG_6531.JPG

    IMG_6532.JPG

    IMG_6533.JPG

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

    Took the rear quarters back to bare metal as the combination of paint and finishing filler was really thick and I've checked there's nothing nasty hiding under it. Also cleaned up and blew in the rear quarter window cavities with my usual zinc primer, followed by 2 pack primer and white paint.

    IMG_6538.JPG

    IMG_6539.JPG

    IMG_6540.JPG

    IMG_6542.JPG

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

    All dressed, cleaned up and primed.

    IMG_6543.JPG

    IMG_6544.JPG

    IMG_6545.JPG

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

    With the rear tubs done, that's the last of the major body metal work. It's taken a lot longer than I wanted but it's been a lot more thorough.

    Little bits of cleaning up and finishing off done. Some chassis fixing holes to fill, extra stitch welding along the front chassis to bulkhead join, welds to dress back etc. Lots of little bits that took a good day.

    IMG_6541.JPG

    This afternoon I've removed the strengthening frame from inside.

    IMG_6549.JPG

    IMG_6551.JPG

    Up next=
    There's a quote for engine, gear box, exhaust etc sitting in my "In box". I'll also be fitting the rear X-pack.
    I've managed to get the original Ford fitting instructions, along with a more detailed set of the original Fibre Sport instructions.
    I'm wondering about using one of the modern 2 part panel adhesives in combination with fibre glass.
    I'll be discussing that with the body shop.

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

    This is the dash top speaker louvre which needs some attention. It was like this when I bought the car, but some how missed it until I got the car home. I need to sort this out. I considered trying to make and weld in the missing louvres, but I don't think that's going to work, it's just too tight. Having had a think, I'm going to cut the louvres out and replace them with a mesh. I'll use the "joggler" on the edges and fit it from below so it should sit flush with the dash top.

    IMG_6552.JPG

    Plan is to fit Blue tooth speakers, and one can still go here.

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

    It’s the wee bits like this that take up the time, easiest way would be to replace the entire section so it’s easier to bring the welds down

    Like the idea of Bluetooth speakers

  25. #221
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thought about replacing the hole grill section, but it's finding a donor one. Easier said than done. I've got the mesh, it's 1.5mm round hole punched, I'm happy that will look right. Looking around it seems to be the choice on most modern cars, and I don't mind a little touch of modernity as long as it's not too obvious.

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

    Worked out the missing brackets from the side kick panels. One each side for the lower trim clips. The panels have a circular pressing that I've not seen on any original car. Think they are supposed to replace the brackets but that would mean drilling a hole, not my idea of good sense.
    IMG_6583.JPG
    so had the pedal box in for working out where's best to fit my reservoirs and run the piping.

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

    Made a start on seam sealing, starting around the back. Going to do this in stages.
    IMG_6584.JPG

    I've altered a spreader so it leaves a finish like the original brush on sealer ford used.

    IMG_6585.JPG

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

    Revisited a couple of things I wasn't happy with, including the bulkhead to wing stiffeners. The welds i did were wonky, and to visible to be left, so I've ground them back, redone them and dressed them smooth.
    IMG_6590.JPG

    IMG_6591.JPG
    Put a new tube in the bulkhead for the clutch cable that I've modified with a flange on it to support/hold the clutch cable more square.

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

    This arrived a week ago. 2.0L Zetec-E. Black Top.
    It's come from a Mk1 Focus Estate Auto, with 57,000 miles which was a police confiscation. So hopefully it's not had a hard life. Had to ditch the crate engine plan as they have doubled in price, making it not economically viable, even if I had to do a full rebuild which i don't think will be required on this engine.

    IMG_6588.JPG

    It arrived with everything except the starter motor, not really the bare engine i was expecting.
    Initial stripping
    IMG_6589.JPG

    Spent a fair bit of my available time on this, this week. Made up a floor stand to keep it stable whilst I stripped and cleaned it. It'll go on my engine stand later
    IMG_6596.JPG
    IMG_6597.JPG
    IMG_6600.JPG

    After a bit of a clean. I've had the cam cover off and it all looks good, no sign of wear on the cams, and the plugs looked really good. Needs a new water pump, but I would have done that with the cam belt anyway. I'll compression test it once its mounted on the Type 9 gear box.

    IMG_6601.JPG
    IMG_6602.JPG

    Got a pallet arriving next week with gear box, exhaust, radiator, throttle bodies and a whole load of bits to put it all together

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

    Today I planned to do a bit more seam sealing, but decided instead to have a look at sorting out the dash top speaker louvres.
    IMG_6552.JPG

    Thought I'd just cut the louvres out and clean up the hole, but once I got into it I've just cracked on, and I'm very happy with the result.
    IMG_6604.JPG

    Accidentally nicked the corner (where more paints been removed) with the grinder cutting wheel, so had to make a weld repair and dress it back. Hand finished the hole with various files, using needle files in the corners to get a small but rounded corner rather than a 90* corner.

    IMG_6606.JPG

    The mesh insert fits really well and is flush with the dash as planned. It's held in here with masking tape.

    IMG_6607.JPG
    IMG_6608.JPG

    Painted the edge of the mesh and the dash top, inside and out, with my usual zinc primer. When It's dry the mesh will be bonded in from below. I'm made a panel to fit over the top to protect the mesh whilst the build continues.

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

    http://www.turbosport.co.uk/attachme...3&d=1571345590

    Hate to criticise anyone else's work but the quarter panel to roof join looks REALLY moody like its just tacked waiting to be seam welded and made invisible? And regarding your speaker mesh mod, I wouldn't bond it before painting - those are pretty small perforations and easily clogged with paint which would look gash - spray separate and stick with silicone after painting finished?

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

    Constructive criticism welcomed, working alone is prone to cock ups.
    That join is stitch welded and dressed back. Originally they are brazed. I don’t have brazing kit. Done the same at the A post join.
    Re the mesh, it’s already bonded in, but I’m confident the guy doing my paint will be able to cope with painting it nicely, it is after all a detail section of the car. Thanks for taking an interest ��

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

    Lovely, neat job on that mesh insert.

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

    Fantastic work, i have been watching (quietly) from the start. i wonder if you could do be a favor? The heater pipework hole in the bulkhead of my car is missing and i need to cut it out. You couldn't take a few measurements for me next time your in the garage could you, maybe a pic?
    cheers in advance and keep up the excellent work

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  37. #231
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks gents for your comments.
    Filstu, no problem, I'll take those measurements for you tomorrow and post them up here for you

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

    Thanks gents for your comments.
    Filstu, no problem, I'll take those measurements for you tomorrow and post them up here for you

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

    Been a busy week but with not a lot to show. Got the seats booked in for recovering, and interior trim booked in for repair and referb. Then there was 5 boxes of engine, gear box, fuel and exhaust parts to unpack and check.


    Garage progress has been focused on the break reservoir fitting. I've deliberated over various methods looking for a straight forward option, but ultimately to get what I want I've got to modify the bulkhead panel.
    Reasons- I want the reservoirs upright and secure, good seals on holes in the panel, easy access for fitting and future maintenance, nice clean pipe runs.
    Space under the upper bulkhead is tight here due to the steering column bracket.
    IMG_6642.JPG

    IMG_6643.JPG

    IMG_6641.JPG
    Separate cover plate so the reservoirs can be assembled and the pipework fed through easily. Rivnut inserts for securing the lid.
    IMG_6644.JPG
    Tacked in
    IMG_6645.JPG

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

    Done Happy with that

    IMG_6662.JPG

    IMG_6663.JPG

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

    Filstu. Bulkhead heater pipe hole measurements
    IMG_6666.JPG
    Line on the left is the inner wing (not it's flange )
    Top line the underside of the top bulkhead flange
    Hashed line on the right is the recess in the centre of the bulkhead
    cross reference the pics below.

    IMG_6664.JPG

    IMG_6665.JPG

    Drop me a line if you need anymore

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  43. #236
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Another good job done. First attempt on mine was without the bonnet on and once installed clashed with the top of the bottles. Wee bit of cursing and then redo

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

    Absolute star thanks very much

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  46. #238
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    Re: 1977 Mk2 Zakspeed Escort. Rebuilding my pride and joy.

    Thanks Donnie, Did all my checks with the bonnet on, there’s not a great deal of room and you have to take account of the bonnet bracing to. The other thing is spacing between the pots, got to take account of the lids so they can be undone

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

    Thanks Donnie, Did all my checks with the bonnet on, there’s not a great deal of room and you have to take account of the bonnet bracing to. The other thing is spacing between the pots, got to take account of the lids so they can be undone

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

    No worries filstu happy to help. ��

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