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Thread: Dubai Mk1 Duratec

  1. #1
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    Dubai Mk1 Duratec

    Well itís all Turbosports fault, endless hours of browsing the restorations section, has led me to buying this on eBay
    Hard to believe I paid £2700 for a 1973 Ford Escort Mk1 with an 1100cc engine, but that having bid on several other Mk1 s and missed lost, this seems to be about the going rate. At least I can drive this down to get shipped, unlike the previous rolling shell I was bidding on.

    EBay Description
    Ford Escort MK1 1973. The previous owner had brought this car from new and was kept in the garage for the last 15 years. It has covered only 59650 miles, comes with 12months MOT, and 5months tax. There is no visible rust on any of the panels, the vinyl roof has no rips or cracks in it. the paint work is in great condition for the age. The underside of the vehicle is solid, with no holes or rust, due to the fact it has been kept garaged. The engine has been given new spark plugs, condenser, and points, and runs like new, starts 1st time every time. Engine size is 1100cc. The interior is very good condition, and original, with the rear side windows that open outwards. Has been fitted with brand new brake shoes all round, and brand new tyres. For the MOT it had a little welding carried out, approx. 4inchs, on the driverís side sill. There are a few light scratches here and there, but not bad enough to spoil the look of the car.











    So, first order of business is to get it shipped out to Dubai, preferably with a few goodies in the boot such as a 2.8i axle with LSD and maybe a Type 9 gearbox.

    The plan, well unfortunately that lovely 1100cc engine is going to have to be replaced, likewise the gearbox, axle, suspension, brakes, interior etc. Once it has all been 5 or 6 linked, roll-caged and room made for bigger wheels, then a leedle 250bhp Duratec might be inserted to freshen up performance. Not looking for the absolute dogs danglies in performance or specification, but the car will be expected to acquit itself with respect at the Dubai Autodrome. I am used to whipping the Evo loving mongrels there in my Caterham and fully expect the Escort to do the same.

    So, as I am a total novice at tintops in general and Escorts in particular, I will be seeking all available advice and input

    www.gulfpetrolheads.com

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    World Champion Decade Plus User Pitstop's Avatar

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    Re: Dubai Mk1 Duratec

    Look forward to seeing this project. Post plenty of pics.

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    Re: Dubai Mk1 Duratec

    Fook me you dont mess about,but that is a mint shell, make sure you keep those seat coversat the end of your project.but will be looking be forward to this one

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    Re: Dubai Mk1 Duratec

    Lookign good there seems like you have found yourself a minter, i myself may be back in dubai next year to work for Gulfsport again, i worked their last year for the 2006/7 radical season and remember seeing your yellow duratec caterham and gave you a hand at a few track days (i was the one with stupid long hair) its a very nice example and if thats anything to go by this will be aswell.

    Nothing is set in stone about me returning yet but if the offer is their i will be, and would gladly lend a hand with anything you need, i am nearing the end of a similar project but a vauxhall instead see here: http://www.turbosport.co.uk/showthread.php?t=102364
    Good luck for the project and may see you in the future.

    andy
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  5. #5
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    Re: Dubai Mk1 Duratec

    Thanks guys, this really is a leap in the dark for me, I purposefully chose what looks like a good shell, as I have no real welding or tin bashing skills yet, so rot replacement is not too high on my desires. Saying that, I do plan to do all the welding myself for the link boxes and shell mods, guess I had better learn fast.

    I will of course do lots of pictures and a propa project diary

    Andy, I do remember you well (well at least the hair). Definitely be keen to meet up with you if you come back out here, are you looking at re-joining Gulfsport?

    www.gulfpetrolheads.com

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    Racer Decade Plus User Joe-Tait's Avatar

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    Re: Dubai Mk1 Duratec

    Great base for a project

    Will keep an eye on this one
    Screaming 1300 mexico rep

    http://i26.photobucket.com/albums/c139/gsijoe/untitled-21.jpg

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    Re: Dubai Mk1 Duratec

    if i come back to dubai it will be working for gulfsport yes but they will not know if they need anyone else until nearer the begining of the season becuase it all depends on the amount of drivers they have etc. im just finishing my degree off this year otherwise i would have been there this year aswell, its annoying the way degree's get in the way of the exciting things!!
    Live Life Sideways

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    Re: Dubai Mk1 Duratec


    Blimey if i dont hurry up i will be the first duratec project to start and the last to finish Keep us posted and if you need any fittmant tips just yell

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    Re: Dubai Mk1 Duratec

    minty looking shell this m8y,well done

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    Re: Dubai Mk1 Duratec

    Nice one Love the carpet, steering wheel cover and seats Reminds me of my Nan's car about 25years ago

    Good luck with the project, fire away with questions

    Good home for it out in Dubai nice and dry!! I visited last year when I was out doing some Diver Rebreather training in Korfakkan, lovely place

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    Re: Dubai Mk1 Duratec

    Love the carpet, steering wheel cover and seats
    Yeah, not sure if they will feature in the final iteration
    Which leads me to my first and potentially most sacrilegious question.
    Bearing in mind I am aiming for a bit of a track car, I have limited storage space and nobody out here is ever likely to need my old parts. What is of no use in the finished car that I can throw in the skip

    Obvious stuff believe it or not, is, 1.1 engine, gearbox, prop-shaft, seats, most of the interior, drum brakes, English axle (eventually).
    What about suspension legs, steering rack, x-member is any of this worth keeping?

    www.gulfpetrolheads.com

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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by dobuy View Post
    Yeah, not sure if they will feature in the final iteration
    Which leads me to my first and potentially most sacrilegious question.
    Bearing in mind I am aiming for a bit of a track car, I have limited storage space and nobody out here is ever likely to need my old parts. What is of no use in the finished car that I can throw in the skip

    Obvious stuff believe it or not, is, 1.1 engine, gearbox, prop-shaft, seats, most of the interior, drum brakes, English axle (eventually).
    What about suspension legs, steering rack, x-member is any of this worth keeping?


    I'd take it to escort-tec on the way to the docks and get them to strip the bits you don't want you'll probably come away with a few quid in your pocket.

  13. #13
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    Re: Dubai Mk1 Duratec

    Well its arrived at last and is installed in my garage. Took most of the interior out today, had a good look at the floor. Not too bad, both front footwells have a bit of rot, but I guess that is normal. I will take the engine out tomorrow and take a few pictures once it is stripped out.

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    Re: Dubai Mk1 Duratec

    Good to hear it's safe and well! Did you get chance to have a look at that axle to see if it's a slipper or not?

  15. #15
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    Re: Dubai Mk1 Duratec

    Good to hear it's safe and well! Did you get chance to have a look at that axle to see if it's a slipper or not?
    Hi Tom, not had a chance to whip the cover off yet, will have a look tomorrow, to busy getting stuck in to the car today.


    Got the car safely into the garage after only minor delays with Dubai Customs



    Stripped out engine, gearbox and propshaft







    Top plates look a bit skanky, do I dress them up or cut them out and re-do (bearing in mind I have never done this before)



    Stripped out interior, drivers footwell looks a bit suspect, time for the screwdriver test



    Well that went well, screwdriver led to anglegrinder...... Now, do I fabricate a piece myself, replace the whole front floor or chop up a repair panel



    Looks like a bit of fresh metal put on top of old crappy metal, hmmmmm, gotta figure how to clean that up



    Passenger side looks a bit better, but a few random plates, hopefully just a bit of a clean up required.

    Will get stuck in tomorrow, got another day in the shed, so should have a bit more idea of the nature of the beast.

    www.gulfpetrolheads.com

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    Re: Dubai Mk1 Duratec

    nice project, i never noticed b4 but urs has got operning rear quater windows, rare they are

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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by cjay2004 View Post
    nice project, i never noticed b4 but urs has got operning rear quater windows, rare they are
    Yeah, I noticed that as well, don't really want them, would prefer the fixed ones

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    Re: Dubai Mk1 Duratec

    Now if you had said that before you exported it i would of quite happily swapped

    As for the floors if you are sure you have got ALL of the rot and thin metal you can butcher a floor panel but by the time you have made it all fit you might as well cut it all out and replace the whole section. Will be easier to hide the joins then aswell if you wish.
    As for the top plates cut them out everytime and replace Its really not a hard job eben for a rookie and theres some good thread showing you how. Check my fby resto thread or any(all) of dave's threads. Theres also a "how to" daves way in the tech section. Its just not worth patching them up

  19. #19
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    Re: Dubai Mk1 Duratec

    Thanks Mat, I agree about the floor and will probably get a repair panel like this http://cgi.ebay.co.uk/Escort-Mk1-2-F...742.m153.l1262

    The strut tops LOOK solid, but on the evidence of the rest of the repairs, I bet they are minging underneath, guess there is only one way to find out

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    Re: Dubai Mk1 Duratec

    Well as I couldn't get the doors off today, even with the removal pin tool I decided to have a peek at the strut tops and as usual with these things, not all was well

    RHS was the worst with plating on top of several layers of rust, looks like the cap and uprights, need changing as well. Just hope I can do it with the wings still on, as they at least are minty



    After chopping out all the crap



    Is anything salvageable from this lot ??

    LHS, fared a bit better, still needs a repair panel, but strut cap and uprights look good





    As always any suggestions or comments gratefully received. as I am on a voyage into the unknown.

    P.S, car officially named as Sveta, as Russian escorts are all the rage out here

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    Re: Dubai Mk1 Duratec

    Looking good, keep going as you are best suggestion if you want it to last is to go over it with a fine tooth comb and chop out all the shit that someone else has put in. Lets face it if its some old grannys car the welding will have been done at a garage and the quickest way for them to turn it around is to just plate over the rust which is why nowdays when you want the car to last you need to redo all the old shit repairs from the monkeys over the years

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    Re: Dubai Mk1 Duratec

    Thought they might be like that
    Just one thing i dont know if you still have the weight of the car on the wheels??? But this is not a good idea when cutting that much of the top plate out

  23. #23
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    Re: Dubai Mk1 Duratec

    Hi Matt, I have a jack underneath the front end to support the weight, might undo the strut bolts in the morning and loosen the load completely. Ta much

    www.gulfpetrolheads.com

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    Re: Dubai Mk1 Duratec

    Got a good days work put in today, shell is now totally stripped (except for the pharking recalcitrant friggin doors that won't leave their hinges) waiting to be sandblasted...



    Found a few more holes in the usual places (spare wheel well) and I explored the damage to the floor a bit more an found that the RHS inner sill is munted, just as well I brought a spare from the UK on my last trip.



    Going to put the car on the spit tomorrow, then off to be sandblasted to find a few more holes.
    Looking forward to start of welding :dood:

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    Re: Dubai Mk1 Duratec

    Looking good, sandblasting is definately one of the best ways to get to know your shell a bit better, wish i had done underneath of mine that way

    Also looks like the drivers a panel has had some shit let in so might be an idea to get that out if its done badly too

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    Re: Dubai Mk1 Duratec

    Got another couple of days work done, bit slow going but some good progress.
    Also looks like the drivers a panel has had some shit let in so might be an idea to get that out if its done badly too
    So, that said.... decided that the wings had to come off. What a pig of a job, the headlight front panel welds were easy enough but the wing to A-panel bulkhead welds were a sod. Took a full day even with my new best friend the pneumatic hack saw to get through all the welds. Hard as fook they were Drip rail was cut easily enough, hope I can put the new ones back on half as easily.




    So on to the job I was really dreading, the doors, which as you can see from the pics above I managed to get removed with the hinges still intact. The Draper tool that I bought was useless, but as I had the wings off, I decided to make up a tool that would allow me to use a FBH with a bit of force . I cut a notch in a cheapo pry bar I had lying around and bugger me if the pins didn't drift out nicely. A couple of them took some good thumps to move but job done



    So with all the major components off now, just tidying up a few of the obvious bad patches with the angle grinder before blasting. This one below was a bit special, what kind of would just plate over a hole like this without even trimming it up.


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    Re: Dubai Mk1 Duratec

    dosnt look too bad but i guess you'll see exactly whats what when it comes back from blasting... im certainly thinking the underseal on my car is hiding alot of nasties.

    keep at it

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    Re: Dubai Mk1 Duratec

    So decided to fix the hole before I sent the shell off for blasting. Trickier than I thought, getting the current and wire feed right for thin sheet is not easy, it really wants more current, but that just pops holes in the steel. Anyway its not the best welding but there are now 2 plates instead of one, as per the original build. Smear of filler and it will be alright.


    As the shell is off getting blasted (hopefully) decided to sort out the 2.8i struts that I bought on eBay and get them ready for coil over conversion.
    Struts all cleaned up & stripped

    Treated with Kurust

    Painted Billie Blue(ish). I will have to strip a bit of the paint to do the welding of course. Now just have to clean up the hubs a bit.


    That's it for now, off on a work trip to NZ for a week, then holidays for the rest of August

    www.gulfpetrolheads.com

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    Re: Dubai Mk1 Duratec

    Lives in Dubai, going to NZ for a work trip, and holidaying for the rest of August.........

    Yep, I ACTUALLY hate you!!

    Good work mate, keep it up!

  30. #30
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    Re: Dubai Mk1 Duratec

    Just as well I didn't mention my hols are in California & Crawley. Doncha just love jet-lag

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    Re: Dubai Mk1 Duratec

    Looking good...

    Are you short of sand out there??

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    Re: Dubai Mk1 Duratec

    Quote Originally Posted by mervhill View Post
    Lives in Dubai, going to NZ for a work trip, and holidaying for the rest of August.........

    Yep, I ACTUALLY hate you!!

    Good work mate, keep it up!


    yep, keep it up

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    Re: Dubai Mk1 Duratec

    Well holidays are over, back to work on Svetlana..
    Managed to get the car up on the spits (modified engine stands). I copied some ideas from Gartrac for the spit mounts, using the rear number plate holder and the bonnet latch bolt location to reduce flex of the panels when the car is on the spit, seems to work well.

    http://www.dubaipetrolheads.com/images/escort/e0038.jpg

    While I was on Hols, I had the car stripped, media blasted and primed. Not the best job in the world, but considering the inherent quality/communication disconnect here in Dubai, it is enough to get going. As always, the blasting has shown up more areas that need a bit of renovation.
    Nasty previous repair to rear panel


    Cheesy floor, not bad but needs repaired


    Boot floor looks bad but have repair panels to fix


    Previous repairs, might need a bit of a tidy up


    Rear sills and arches, planned steel bubble arches and inner tubs fillets will fix a lot of this


    Cut out driver side floor pan rot and sill. Most of sill is good, not sure if I need to replace or patch it




    Rust hole in chassis rail, should be easy to fix


    So here are my questions for today from the panel of experts...
    1: Do I patch the sill or replace it, bearing in mind most of it is solid?
    2: Do I repair the sill first before welding in the floor repair panel?
    3: I am fitting a Rally Design big gearbox tunnel, do I keep that centre U shaped brace just to the rear of the gearstick hole?
    4: Is there any point in keeping the spring hangars, as I donít ever see me putting leaf springs back on?

    Any advice or comments always gratefully received as this is a voyage of discovery for me

    www.gulfpetrolheads.com

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    Re: Dubai Mk1 Duratec

    Looking good mate, money well spent in my eyes....thats done what took me a good week or 2 in total time just on the underside....all you had to do was sun yourself on holiday

    Secondly you mentioned tidying up the old repairs. If you want the shell to be perfect and last then i would be chopping it all out and doing it yourself, that way you know its all done properly with no nasty bits hidden below a solid looking plate

    Then to answer your list:

    1: Do I patch the sill or replace it, bearing in mind most of it is solid? If you feel you can patch it in well enough then do that, theres no point chopping out good metal just to use a whole pattern repair panel. I would just replace the rot, that way you will end up needing less filler work to get it all straight again. Rear arches are a prime example for people chopping out more than they need to and fitting the whole repair panel and then needing a ton of filler to straighten the 1/4 from the distortion and also blend the arch
    2: Do I repair the sill first before welding in the floor repair panel?Having done my sills after the floors, i would say do the sills first, then you have a point to work to especially if you let a patch in like above as you will have a nice line/panel to work to. Would have been better if you could have left the old sill and done the floor or vice versa but i guess you got a bit happy with the cutting disk on the grinder...thats dave roberts' fault
    3: I am fitting a Rally Design big gearbox tunnel, do I keep that centre U shaped brace just to the rear of the gearstick hole? It cant do any harm to keep it should it meet with the new tunnel, you may well find that the tunnel is wider and taller in that particular place though and so it wont fit so you might want to knock something similar up as its probably quite important to stop flex.....that said mine has no top section from when i did my t9 conversion
    4: Is there any point in keeping the spring hangars, as I don’t ever see me putting leaf springs back on?
    if your going for a 4 link then your right theres no reason for them to stay, they are only spot welded on and not part of the structure so lose them, i guess people just leave them on the save having to chop them off


    Also if you need any ideas for the chassis rail repair then look on my thread i had to do it on both sides in that place. I see you cut the rot out from the bottom of the rail section, just make sure theres no hidden rot in the sides where the two sections overlap as its common for the whole overlap to hold the moisture/rot and blow the sides as well as the bottom, usually long after the bottom blows out

    And finally keep at it, jig looks very well made and thought out and with the shell the way it is you should fly through it seeing as you dont have the shitty task of getting all the crap off the underneath

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    Re: Dubai Mk1 Duratec

    Brilliant Dave thanks for that, I had a look at some pictures of other 'restorers' tunnels and they had all kept the U shaped thingy. Most of that sides sill was double and triple repair plates or rust, hence why I cut it out, although I might have been influenced by others radical surgery as you state
    Will get started on the sill today and see how I go

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    Re: Dubai Mk1 Duratec

    The only way to tell if it can stay is to fit the tunnel and see. Take your time and drill out the spot welds and keep it in place, and if its miles away then chop it off and make something up from it that will work

    I figured there was probably little for you to work from that side as we all know how rotten these cars can be Start with the sill i recon, maybe just get it all trimmed down and tack it in place (so you can chop it off again should it turn out to be wrong), then get the floor in place too using it as a guide and then you can decide what needs to move from there. I would say use only as much of the floor panel that you need to as with the sill, but looks like the whole things gone just make sure you get the seat crossmembers out before you do the floor, that way you can make a much neater and stronger floor and also you can probably leave the xmembers out if your going for seat bars, obviously gary will know if they need to go back in for strength reasons?

    Crack on

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    Re: Dubai Mk1 Duratec

    OK so got started with the driver side floor and sill. Cut out all the rot from the inner sill, cleaned it up, weld-thru zinc primed it and put the repair panel on top. Was fairly easy to fit, but has (like they all seem to) a big cut out for the seat cross member.



    Also patched the RHS kick panel and then put in the floor repair panel. Struggling with getting the welding as neat as I would like, but it is getting better all the time, so by the time I have got to the aesthetic parts I should have the hang of it. Also repaired the nick I put in the chassis rail with the angle grinder



    Finally put in a plain patch to fill the space where the seat cross-member was as well as the sill cut out.



    So that is one side done, except for the gearbox tunnel

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    Re: Dubai Mk1 Duratec

    You're making good progress there, keep it up!
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    Re: Dubai Mk1 Duratec

    Looks nice and neat from where im sitting

    All these other restos dont half raise the bar for when you come to do your own dont they

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    Re: Dubai Mk1 Duratec

    Thanks Dave, I am purposefully not showing off my welds too close up as they are still not as neat as I would like, however they are getting better, by the time I have done my second car they should be good

    Picked up another angle grinder the other day in Ghana of all places, £10 and very nice it is too,

    You just canít have too many of these

    So next little job is the outer sill. I thought about patching the sill, but figured it was probably better to replace the whole thing as who knows what lurks beneath. Sure enough there was a fair bit of corrosion in the mounting plate towards the wheel well.


    I managed to remove the rear sill mount plate fairly easily and it was just as easy to make a neat new piece, then onwards to sill fitting.



    Ready to fit outer sill






    Bit of a sod to do, when you are doing your first one, big mistake was to hit it (as suggested elsewhere) to get it to close up to the floor pan for welding. I made the mistake of hitting a piece of wood with a FBH and unfortunately I left a bit of a dent in the sill face. Still should be able to ease it out, if not, itís nothing a bit of filler wonít fix.

    Next thing little job was to patch the chassis rail.

    I plated the hole with a bit of 1.5mm plate, then weld-thru primed it and put a repair piece on top and seam welded it into place.

    First repair plate


    The patch


    Finished


    Sounds real easy when you say it quickly, but took me Ďkin hours to get the replacement piece fitting nicely, especially as I have no sheet metal folding tool (apart from the FBHís of course). Pretty happy with it, should be plenty strong enough now.

    Couple of days break (work), then start on the other sideís floor and sill area, which is in a bit better shape.

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