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Thread: Dubai Mk1 Duratec

  1. #81
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    Re: Dubai Mk1 Duratec

    Thanks Guys, it is really nice out here at the moment, getting to work with the garage open, although getting all kinds of weird looks as the natives here are not used to seeing anybody working on their own car, it's unheard of! Not to mention a 35 year old car, when 4.5 years is regarded as an old model out here.

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  2. #82
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    Re: Dubai Mk1 Duratec

    Nice work.


    Obstacles are those frightful things you see when you take your eyes off your goal.



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    Re: Dubai Mk1 Duratec

    Really am enjoying this one..........some great fab. work

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    Re: Dubai Mk1 Duratec

    NIce Job! finished in no time at this rate!

  5. #85
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    Re: Dubai Mk1 Duratec

    Well the last of the old expert repairs enticed me to have a look underneath. Every other repair had severly corroded metal below the repair plate, so why would these ones on the ARB mounts be any different

    Looked OK from outside..... but


    And the other side


    Cleaned up of all loose rust and KuRust treated


    Rust replaced with good metal


    ground back


    And inner wing plate added


    Next job is on to the body modifications, first off is the front bulkhead reinforcement panels

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  6. #86
    Pit Crew Decade Plus User 105Ian's Avatar

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    Re: Dubai Mk1 Duratec

    Keep up the good work

  7. #87
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    Re: Dubai Mk1 Duratec

    So on to the link boxes for the Atlas axle torsion bars. Spent much time measuring the inside of the car, until the penny finally dropped and realised it was the underneath I should be measuring. My axle diamond brackets are 780mm apart, so the center of my boxes has to be that as well. Using the chassis rail and leaf spring brackets as a reference, I created 2 parallel boxes on the floor pan that start at the bottom of the seat crossmember and extend the length of the boxes. The boxes are about 52mm wide.


    Received wisdom is to fold up the floor pan to form a lip of about 10mm or so to weld the boxes, so duly did this, cleaning paint off the floor pan before lipping it to save time later.


    Box getting trial fitted, spent a bit of time trying to figure out how far they protrude. I ended up with the top of the box being about 62mm above the seat crossmember.


    All welded in


    Decided to go for spaced welds, as this is reckoned to be plenty strong enough




    Underneath with the excess edges trimmed off




    Here you can see that the back edge of the box requires a bit of the chassis rail edge to be trimmed

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  8. #88
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    Re: Dubai Mk1 Duratec

    Cracking work as ever gary did have a nice drawing somewhere with the dimensions on but i guess its too late now

    Are you going to notch the chassis rails for extra axle clearance too?

    Keep it up mate

  9. #89
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    Re: Dubai Mk1 Duratec

    Not sure what is involved with the axle notching Dave, quite happy to give it a go if it is worth the effort

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    Re: Dubai Mk1 Duratec

    It is if your planning to run the car low! Have a look through some of garys creation threads, i think both al's and marks' cars had the notches in the chassis rails. Or if gary sees this he might just have the pics to hand!

    It seems pretty simple, just chop a curve into the chassis rail where the bump stop plates are and let in a curved piece of thickish steel so it gives the axle clearance at full travel upwards

  11. #91
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    Re: Dubai Mk1 Duratec

    Cracking work as always
    I think i'm going to link an escort one day. Just something i feel i need to do at some point in my life

  12. #92
    Mechanic tezscort's Avatar

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    Re: Dubai Mk1 Duratec

    Great work there mate, keep the pics coming
    Of all the things I've lost, its my mind I miss the most.

  13. #93
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    Re: Dubai Mk1 Duratec

    Thanks for the encouragement Gents. Decided it was time to cut another hole in the floor pan...


    Filled it with the bigger diff tunnel, all pretty straight forward


    Then on to the cross braces, wasn't sure whether to overlap these in the middle or butt fit them. In the end overlapped them as I perceived it would be a bit stronger. Again a pretty easy job.


    Cleaned up and Zinc'd


    Having a (GWD) good welding day so decided to fill in the fuel filler in the wing, as I will fit a boot filling tank for racing. Luckily enough my just finished coffee cup was the exact size of the hole, so drew round that and nibbled out a repair piece. Quick wiz with the Mig on a low setting and all came out pretty good.


    Inside the boot


    Will need a little panel beating to get perfect, but is within about 1mm as it stands now.

    Got a feeling tomorrow might bring an even bigger hole....

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    Re: Dubai Mk1 Duratec

    Definately looks like a gwd to me

    Whats the bigger hole then as i thought it was almost there now your fitting all your fancy fabricated bits?

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    Re: Dubai Mk1 Duratec

    nuff respect some nice work there buddy coming along nicely
    if it aint broke, break it!

  16. #96
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    Re: Dubai Mk1 Duratec

    So here is the hole I promised, I guess it's not as dramatic if it is not in the floor



    Now big plea for help, as you all know this is my first go at all this and my technical help line is you lot

    However I want to not phuk up the turret installation, as I think the axle geometry might be important So i Have started a new thread to try and create an idiots guide to fitting round turrets. Anyone with any experience on this, your comments would be gratefully received http://www.turbosport.co.uk/showthread.php?t=137980

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  17. #97
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    Re: Dubai Mk1 Duratec

    Nice work again Dobuy.I think the turret intallation guide is a good Idea.

  18. #98
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    Re: Dubai Mk1 Duratec

    looking good there

    MY MK1 ESCORT (Now turbo'd)

  19. #99
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    Re: Dubai Mk1 Duratec

    OK, well on to the turrets, after much deliberation and measuring time to cut another wee hole





    Then in with the turret, sounds really easy when you say it just like that, but it is a little nerve racking the first time round. As usual I cut a bit too much metal away on one side, nothing a quick tap out with a hammer didn't fix tho'. Welded it on the inside of the car





    Which left these big flanges in the wheel arch



    Trimmed them back to about 15mm, then folded them over with a bit of heat and a dolly



    Quick lick of zinc et voila. Just have to wait for a week or so, before I can do the other side as I need to wait for my Welsh delivery service to give me the Left hand side one in exchange for the second right hand one I have in me shed.

    Still I am sure I can find a few other bits and pieces to do, I guess I can always cut the other hole in anticipation

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  20. #100
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    Re: Dubai Mk1 Duratec

    So while waiting for my other turret to turn up, decided to notch the chassis rail below the axle for a bit more clearance at low ride heights. Copied a couple of photo's I took at Gartrac earlier this year, looking at other photo's I have seen more radical notching, but wanted to keep at least 25-30mm of chassis rail.

    Here is the standard rail, after removal of bump stop


    Then the finished item, after plating with a bit of 1.4mm steel


    And the side with the turret already installed

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  21. #101
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    Re: Dubai Mk1 Duratec

    Well, I must be boring you lot to death, 3 posts in a row with pictures

    Started doing the rear inner wheel arches. Using the tried and trusted cardboard template to get a rough shape


    Translated it to steel sheet


    Then lots of massaging with a flap wheel to get the required shape. Bit fiddly but eventually got there, used self tappers to hold in place all the way round, before welding.


    Will need a touch of seam sealant to fill in the odd 2mm gap, but otherwise should be fine.


    Finally got the other turret in, was a little less fiddly than the first. Simple things make the difference, cleaned up the metal all round well before I tacked it in place, made welding much easier.


    Also put a bulkhead panel on the engine bay bulkhead and a couple of the chassis rail corner stiffners.


    Next job, the boot floor and Watts towers

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  22. #102
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    Re: Dubai Mk1 Duratec

    Looks good, won't be long before you're ready for paint.

  23. #103
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    Re: Dubai Mk1 Duratec

    You forgot the holes from the cardboard template
    Looking good
    67 TVR VIXEN V8

  24. #104
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    Re: Dubai Mk1 Duratec

    very nice

  25. #105
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    Re: Dubai Mk1 Duratec

    Looking very nice well done

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    Re: Dubai Mk1 Duratec

    Great work as ever your flying through it mate

    And think yourself lucky you got 3 posts of pics in a row, i usually get about 3 pages of abuse between posts on mine Dont let it get to you, theres a lot of people out there who look and appreciate the pics but are too shy to post to say they like it

  27. #107
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    Re: Dubai Mk1 Duratec

    i usually get about 3 pages of abuse between posts on mine
    abuse, I dream about abuse

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  28. #108
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    Re: Dubai Mk1 Duratec

    Excellent work as usual
    Wish i could get that much work done on mine, but then -3C aint that appealing to do anything.

  29. #109
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    Re: Dubai Mk1 Duratec

    You're making rapid progress..!

    Its gonna be great.

  30. #110
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    Re: Dubai Mk1 Duratec

    excellent fab and welding work there bud,looks a minter shell as well to start with.as dave said your flying through it by the looks of it.keep it up

  31. #111
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    Re: Dubai Mk1 Duratec

    Wish i could get that much work done on mine, but then -3C aint that appealing to do anything.
    I know what you mean, I had to wear a t-shirt under my overalls 'tother day, as it was 19'c in the morning

    Looking at my pictures do you think I need some more welds between the bubble and new wheel arch fillets, or does the spacing look OK/enough

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  32. #112
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    Re: Dubai Mk1 Duratec

    Id say a couple of tacks like you have should be enough, your filling it with sealer anyway. I would have tubbed to the 1/4 and then spotted the arches on top of the 1/4 just incase the arch takes a whack ever. Both ways are ok though and its too late for you to change it

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  34. #113
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    Re: Dubai Mk1 Duratec

    Great work - definitely not boring us with all the pics

    It must be tough going working in those temperatures

  35. #114
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    Re: Dubai Mk1 Duratec

    Well big day today, sorted out the boot floor modification for the Watts link tower and then threw the axle on with the link rods


    Boot floor inside, before tidy up


    Was pleased to see that everything matched up pretty well on the money as far as link bars and turrets went. Likewise the bubble positioning looks pretty good


    However one thing not sure about is the Coil Overs, without the springs and the damper compressed all the way to the bump stop there seems to be a lot of clearance between the axle and the floor and chassis rails. The only thing I can think of, is the bump stop needs to be chopped down a fair bit, either that or my dampers are too long. So can I chop the bump stops ??
    Only other option is to take out/cut down the rubber bung at the top of the damper/below the turret.

    note: in this picture the axle is leaning to one side and is not central

    One other question for the audience, roughly what is the required angle of the axle/diff head do I can set up my bottom links correctly?

    I am going to fit the Watts Towers tomorrow, I did the "fit adjustments" today to the towers to get a nice fit on the chassis rails and floor, so should be just a matter of welding them in

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  36. #115
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    Re: Dubai Mk1 Duratec

    looks great, and an inspiration to many.
    I wouldnt cut the bump stops. What angle are the arms at when in the phtos, are they parrallel to the ground or raking up towards the boot. If inverted in your mind? If they would be parrallel when inverted then the shock absrbers may be too long.
    A few things to check before you hack away at things. Keey up the good work.

    Cheers,

    JP

  37. #116
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    Re: Dubai Mk1 Duratec

    I'd take the bump stop off completely and see how much more travel the dampers have before bottoming out, otherwise you may cut the bump stops and find the damper bottoms out before the bumpstop comes into play.

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  39. #117
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    Re: Dubai Mk1 Duratec

    Thanks Perky, good suggestion and I did just that, damper closes up to almost totally cover the rod, maybe a couple of mm at most. With the damper closed completely (without bump stop) the diff is on the floor of the modified boot and the top link bars are almost resting on the base of the boxes.


    So I guess that is fine, still plenty of room on the chassis rails, so am fairly happy with it all, just have to decide whether to take a bit off the bump stop anyway


    I popped my Caterham lightweight 8x13" wheels on to see if they would be OK for offset etc. Looks pretty good, save me buying new wheels to get started with


    Got the turrets welded on, fairly simple job, however for some reason my welding machine did not like doing good welding until I had been going for about 20 minutes, must be the humidity I guess Anyway all cleaned up


    Still got to do a couple of bracing plates a la Gartrac for the towers, but that can wait a while.


    Off to blighty for a week's Escort shopping and to enjoy some of that nice cold weather

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  40. #118
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    Re: Dubai Mk1 Duratec

    Nice work, looks nice and low with that wheel in there! Sounds like cutting the bumpstop is the best solution for the time being then?

    You must be mad coming here for a break!!! Where abouts are you staying/visiting?

  41. #119
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    Re: Dubai Mk1 Duratec

    Looks really neat

  42. #120
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    Re: Dubai Mk1 Duratec

    Hi Dave, I will be staying in Crawley, W. Sussex. But plan to visit the badlands of Surrey, Essex and Kent on my scavenge for parts. You may think it's mad but I miss civilisation after being in the Middle East for 15 years

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