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Thread: My New Project ( Millington Escort) to stop me using this

  1. #1
    Spanner Monkey genRS2000's Avatar

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    My New Project ( Millington Escort) to stop me using this

    Hi. This is my 1st post so I hope I get it right. I am in Perth Western Australia and have a genuine Mk1 RS2000 that use for sprints and hillclimbs. Now there are not many MK1 RS2000s in OZ as they were never sold here so it is now quite valuable so I need to stop using it for motorsport and return it to road car( it is mechanically highly modified ).




    My new project is a Escort Mk2 that will be modified Group 4 style.









    It has been sitting in a field for a couple of years and has a bit of rust but not like rust in the UK... look at the strut tops!

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    Re: My new Project to stop me using this

    I'm not sure you should be allowed to put this in the resto section

  3. #3
    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    Why? The forum does say show us your project whatever it is.

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    Re: My new Project to stop me using this

    Quote Originally Posted by genRS2000 View Post
    Why? The forum does say show us your project whatever it is.

    I'm sure Dave is just joking. The car looks so good at the strut tops, it almost don't need any restauration .

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    Spanner Monkey LOW'N'SLOW's Avatar

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    Re: My new Project to stop me using this

    Very nice, looks like a great base for the project.

    Look forward to seeing the updates.

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    Racer Decade Plus User Stringpants's Avatar

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    Re: My new Project to stop me using this

    That scratch should T cut out....

    Keep the pics of the restoration coming,

    Good Luck,

    Russ.

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    Spanner Monkey flyingbenny's Avatar

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    Re: My new Project to stop me using this

    Two rear wheel drive Escorts AND you live in Perth, the nicest place ever, you must be the luckiest person in the world.

    Keep us updated but please keep the background scenery to a minimum, it makes me want to be there

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    Pit Crew Hoogi's Avatar

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    Re: My new Project to stop me using this

    All in all that looks like a pretty solid MKII.

    What's your time-scale..........are we talking months or years

    By the way love the MKI RS

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    Spanner Monkey rallyladgaz's Avatar

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    Re: My new Project to stop me using this

    very nice mk1 ..... that mk2 shell looks solid wish they were like that over here after being stood in a feild keep us updated on progress

  10. #10
    Mechanic mk2 wizard's Avatar

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    Re: My new Project to stop me using this

    Nice mk1 it would be a shame to damage it , but it still needs to be driven hard

    Mk2 looks so soild your so lucky to have the weather on your side that your cars last keep us up dated with plenty of pics

  11. #11
    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    OK no more scenery just more photos of the car in my shed.
    I hope to have the shell repaired, modified to Gp 4 and painted in 4 months and then to start fitting it out mechanically so it will be ready for competition next year.I have been buying parts for it from the UK as the exchange rate for us Aussies is really good at the moment. I will be taking the motor, probably the gearbox and the front suspension and brakes from the RS.

    Have been busy with the angle grinder cutting out rust and the sound deadening.








    Had to cut some sections out of a donor wreck that I have to weld in where the rear pillars have rusted and the front panel was damaged.




    Waiting for a new tip for my MIG before I can start welding

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    Re: My new Project to stop me using this

    Looks good, sure you are not just cutting out a few bits so you can fit in here with the other rust junkies

    www.gulfpetrolheads.com

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    Re: My new Project to stop me using this

    sounds like a real nice project you have

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    Re: My new Project to stop me using this

    looks a good project ! i did exactly the same on my boot corners !!

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    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    looks a good project ! i did exactly the same on my boot corners !!
    That is very interesting as I have never seen another Escort that has rusted in the rear pillars. Someone suggested that it may have had a vinyl roof to cause the rust It could have as it is an auto and had factory aircon fitted which was uncommon in 1980 even in OZ.

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    Re: My new Project to stop me using this

    Quote Originally Posted by genRS2000 View Post
    That is very interesting as I have never seen another Escort that has rusted in the rear pillars. Someone suggested that it may have had a vinyl roof to cause the rust It could have as it is an auto and had factory aircon fitted which was uncommon in 1980 even in OZ.

    hi mate good luck with your project,
    we have had loads of mk2s like that back from oz its quite a common problem its as if no sealer was put in the seam when car was made , all the ozzy cars have mint inner wings and chassis rails just small bits to do here and there ,if anyone wants one just give us a buz, cheers mark
    Breaking MK1 & MK2 Escorts, all models
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    Mob: 07855 985220 email: hewd11@yahoo.co.uk


    Please visit our website: www.escort-tec.co.uk
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    Tyre Kicker turkishjohn's Avatar

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    Re: My new Project to stop me using this

    love it . my mk2 was the same colour when i got mine and it was a auto
    Last edited by turkishjohn; 18-04-2009 at 08:08.

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    Re: My new Project to stop me using this

    lived in perth for 11 years.

    dont remember seeing many escorts at all.

    very popular with the Z cars though.

    I lived in Woodvale and went to school in Balcatta out of interest

  19. #19
    Part of the furniture Decade Plus User trig's Avatar

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    Re: My new Project to stop me using this

    Nice one

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    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    lived in perth for 11 years.

    dont remember seeing many escorts at all.

    very popular with the Z cars though.

    I lived in Woodvale and went to school in Balcatta out of interest

    Plenty around in the 70s and 80s. Only used by enthusiasts and motorsport people now.

    When were you here?

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    Re: My new Project to stop me using this

    this is my mk2

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  23. #22
    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    Finally got a new tip for my MIG. I needed a 0.6 mm one because I have not welded thin stuff before. The only tip in Western Australia was 800 km away and I can't believe it took 2 weeks to get to the place I ordered it from. I can order stuff from the UK and have it delivered to my door in 4 days! Anyway rant over. Have been fabricating and welding.

    New wing rail to replace the old one that was rusty underneath.

    Not having a heater so have replaced the plenum with a flat panel that is bolted on.

    Rivnuts inserted so the fresh air grill can be bolted on.

    Countersunk so the bolts are flush with the panel


    Welded a section into the front panel were it was dented


    Made up some new seat crossmembers
    Roll cage arrived today, will be welded in when turrets and link boxes are in

  24. #23
    Mechanic oxb1l's Avatar

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    Re: My new Project to stop me using this

    Looking Good !

    i think the hardest part of this project will be pulling that mk1 to bits

    L8r Bill

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    Re: My new Project to stop me using this

    looks a good project and the mk1, wish mine had that little amount of rust

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    Re: My new Project to stop me using this

    Have you got any update photos?

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    Re: My new Project to stop me using this

    Sweet looking project, more pics
    Ant

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    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    There hasn't been any progress as I hurt my back 3 months ago and haven't been able to work on it. I am well pissed off.

  29. #28
    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    Well finally my back is a bit better so I have done some work on the car.
    Next on the list is 4 linking the rear. I had bought a Gartrac 4 link box kit but after reading Gary's (Retromotorsport) threads about rally and race cars I decided to make my own as my car will be used for hillclimbs and sprints so needs to be as low as possible using what Gary had done on Andy Pipe's car as a quide.

    First I made the body brackets for the front of the link bars and tacked them in. This sounds easy but it has taken quite a bit of time and effort to get it right.



    Next I had to make the link bar covers. I wanted to copy the Gartrac ones so I had to put a flange on the lower lip to follow the floor profile. Made up a wooden former to do this.



    It has worked surprisingly well, just needs a bit of adjustment and will fit perfectly.





    Have to do the other cover which won't be as easy as the floor profile is not the same.

  30. #29
    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    Have now done the other link cover. For the RH one I used a cardboard template



    for the LH one I decided to use to pieces of wood to get the side profiles and then I could use them as formers for the flanges









    Next is the large diff tunnel

  31. #30
    Spanner Monkey Luke's Avatar

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    Re: My new Project to stop me using this

    Nice work mate, I would definately being doing taller boxes again if I redid mine.Good luck with the rest of it and I will have to come see it go when its all done.

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    Re: My new Project to stop me using this

    Quote Originally Posted by SANTA View Post
    Nice work mate, I would definately being doing taller boxes again if I redid mine.Good luck with the rest of it and I will have to come see it go when its all done.
    Thanks mate. Will be glad to show you when its finished.


    Large diff tunnel is the next job.
    Now there was 2 ways I could have done this.
    THE EASY WAY. Get one sent from the UK from one of the many suppliers( GARTRAC have them on special at the moment for £15) but it would cost £80 or more to send it to OZ because of the weight/volume calculation.

    So I choose the HARD WAY. Bought a sheet of 1.2mm steel for $70 (£38) to make my own. The biggest problem was that bend at the rear needed a tiny radius but at the front the radius had to be quite large. My first attempt was no good so I rejected that and had a think.



    Decided to try a wooden former shaped to give the right profile.



    I used a cardboard template to get shape and then clamped the steel to the former and wacked it with rubber mallet.



    The end result was OK



    So I cut a hole in the floor and tacked it in.


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    Spanner Monkey trip998's Avatar

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    Re: My new Project to stop me using this

    that's coming along nicely. keep the pictures coming, it's great to see others attempting the jobs i hope to be doing next year.
    is that an auto tunnel? i presume you are leaving it as it is!

  34. #33
    Mechanic gpcmatric's Avatar

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    Re: My new Project to stop me using this

    Nice one very

  35. #34
    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    Quote Originally Posted by trip998 View Post
    that's coming along nicely. keep the pictures coming, it's great to see others attempting the jobs i hope to be doing next year.
    is that an auto tunnel? i presume you are leaving it as it is!
    Yes it is an auto tunnel . The shell I got just happened to be an auto

    On to the 4 links. axle and turrets.
    I would really like to use a fully floating Atlas axle but I can't afford one and I also want to keep the weight down. Here in OZ people tend to use a Hilux axle but I want to keep things FORD. I already have a English TRAN - X 4.44 LSD with Atlas side gears and Atlas diam halfshafts in my current car so I am going to use that in a fully floating English casing built to Atlas length and with Atlas halfshafts. Now I know you will be as English axles are crap but I will try it and if it breaks I will and save for an Atlas.

    So here goes:

    Axe in place and centred



    Link brackets tacked on. The bit on the end is to adapt a Atlas stub axle onto the English tube.



    Hub and wheel in place to get the the required axle length





    On to the turrets. Spent most of the day in the shed measuring and then inside( it is 37º C here today so I needed to come into the aircond sometimes) checking Turbosport posts ( mainly Guru Gary Retromotorsport) so that I got everything right. Main thing was to get the turret height correct so that the Bilstein coilovers are at mid travel at the static ride height.
    A lot of needed. The turrets ended up a bit higher than normal as the dampers are really made for rally cars not my low hillclimb car. They are also tilted slightly forward and inwards according to Gary's ideas. Hope I have got it right.



    Turret in place with the chassis rail notched to get maximum axle travel.


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  37. #35
    Pit Crew Hoogi's Avatar

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    Re: My new Project to stop me using this

    Well you've impressed the shit out of me...........like to see people doing it their way.

  38. #36
    Bodger

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    Re: My new Project to stop me using this

    looks good mate! i want an aussie mk2 shell now

  39. #37
    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    Haven't done much lately as while it is snowing in the UK it is around 37º C here.

    Decided to put in an exhaust tunnel.





    Checked the clearances for the coilovers. Just enough between the spring and the turret but will probably need spacers to get enough clearance for the tyres. Will check properly when the Watts Link goes on.


  40. #38
    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    Well it has been nearly a year since I have updated this thread so here is the latest.

    The exchange rate between the pound and the Aussie dollar is really good atm so I have decided to use an Atlas axle and not an English as before. So I have got a bare casing with thick tubes to build it. Also got a Watt's Link mount with adjustable pivot.




    Welded in the turrets, link boxes and the exhaust tunnel ( the rust shows how long it had been neglected)





    Wasn't happy with the diff tunnel so I cut it out and made another one ( this is the 3rd one I have made )






    Decided to cut out the section between the turrets and brace them with some CDS tube



    and part of the boot floor

    I wasn't happy with the standard of my welding so I did some research on the WWW to find out where I was going wrong. Got some good info from this site.

    http://www.weldingtipsandtricks.com/

    My earth clamp looked pretty crappy so bought a new one with copper inserts as advised on the site. The other problem was having difficulty seeing the weld so a threw away my old welding helmet and bought a new Speedglas. It is brilliant , I can now see what I am welding.

    Offered up the Atlas to work out where to mount the Watts Link





    More to come, with plenty of photos

  41. #39
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    Re: My new Project to stop me using this

    good stuff and great work with the wooden formers

  42. #40
    Spanner Monkey genRS2000's Avatar

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    Re: My new Project to stop me using this

    Back too fabricating inside the car.
    Welded some reinforcing plates onto the turrets. This is where the backstays for the roll cage will be welded. Much happier with my welding now.



    Replaced part of the boot floor with a flat section. The channel on the right will be for the exhaust. Also cut the entire rear shelf out. It will be replaced with an aluminium panel that will be sealed so it will be a fireproof bulkhead.









    Next up was fabrication of the ally bulkhead. I had to take it in and out many times to get an accurate fit.







    Had to cut holes for the top of the turrets as the panel will be folded to be in front of the turrets not between them.





    Welded some collars to the the turrets. These will stick out through the bulkhead and will be sealed.




    I wanted a nice sharp bend in the bulkhead so I took to a mate who makes motocross trailers and got him to bend it.


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