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Thread: Mk1 Escort Door Pillar Rust

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    Pit Crew Decade Plus User MK1_Oz's Avatar

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    Mk1 Escort Door Pillar Rust

    I knew I had some rust pinholes in the outer door pillars on my Mk1 Escort but upon making an exploritory hole it would appear that the rust is more substantial than I hoped (sorry, I know this is minor to what you have....). This picture doesnt really show just how deep and flaky the rust is on the inner panel.




    It is most likely that this rust is over the entire surface of the inner panel. I would like to remove the rust and have some peace of mind. How do I go about removing the outer door pillar panel??

    From what I can tell I need to unpick the spot welds on the sides of the panel, I expect there are more on the front face of the panel (where ?). I then thought I would cut the panel at the locations shown by the white lines in the first photo.




    Can anybody help me out with any info and suggestions you have please????? Cutting this section off is by far the biggest and most scary incission I have done yet.....

    PS - Dave note the hammers.........
    1970 Mk1 Escort Tarmac Rally Car

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    Pit Crew Decade Plus User MK1_Oz's Avatar

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    Re: Mk1 Escort Door Pillar Rust

    Had a further think and poke. The double skin section of the door pillar is on the right hand side only (when looking at the pillar). I therefore am now thinking that there is no real advantage of taking the whole outer skin off (other than maybe cleaning up any rust that has formed within the joint) so pehaps I should cut it off as per this picture?

    1970 Mk1 Escort Tarmac Rally Car

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    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk1 Escort Door Pillar Rust

    Personally I'd replace the entire A pillar skin, as that will save you having to do a long seam weld down the face of the skin which could lead to distortion.

    The best way to find spotwelds is to thoroughly go over the whole area with either a flap wheel or a wire brush in a drill, this will show up the spot welds a low spots in the panel. Drill out the ones you can see, any remaining ones will reveal themselves when you try to remove the panel!
    http://escort.accelerator.org
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    Pit Crew Decade Plus User MK1_Oz's Avatar

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    Re: Mk1 Escort Door Pillar Rust

    I was not goingt o replace the entire skin but only the rust section I have already cut out and also the bit on teh front face in the middle (near where the door strap connects). Would you still replace the entire skin? I suppose I still have the long seam weld issue is I only put patches in...
    1970 Mk1 Escort Tarmac Rally Car

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    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk1 Escort Door Pillar Rust

    It's just my personal opionion, but I just think that replacing the entire panel is easier and tidier - assuming you have the panel! I've patched stuff like that in the past when I've been skint or no panels were available, it's perfectly acceptable.
    The other reason to replace is that over here at least there would almost certainly be rust in the joint where the A post meets the splash panel, what you've got there I wouldn't even describe as tarnished
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
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    Pit Crew Decade Plus User MK1_Oz's Avatar

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    Re: Mk1 Escort Door Pillar Rust

    thanks exboyracer. I do feel guilty asking questions about my 'substantial' rust problems

    I do not have the panels and would have to get some direct from Expressed - not cheap to buy or freight. Will see if the funds are available for new panels as I agree it would be a neater job. I will either use those or remove the panel at the spot welds with minimal cuts across the top and bottom.

    I am trying to drill out panel join spot welds and clean up inside the joints just for peace of mind but as you know this is a laborious and long process (but then the car will last another 40 years over here!)
    1970 Mk1 Escort Tarmac Rally Car

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    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk1 Escort Door Pillar Rust

    Hadrian do the A post skins, they're a reasonable fit from memory
    http://hadrian.dominohosting.biz/had...cument&Ret=ALL
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
    1972 MK3 Cortina 1600XL
    1984 Sierra XR4i
    And other junk I don't like to talk about!

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    Re: Mk1 Escort Door Pillar Rust

    I was just going to patch mine up as the a post only had a few very small bubbles .But when i saw the amount of surface rust between the the door hinge support panel and outer skin i was glad i chopped it all out .My final reason was the fact of where its too and when the cars all finished i didnt fancy having to take doors off at a later date .It was the same thing with the heater bubble looked mint until i took it off ,was not rotten but would not of lasted the life of the paint job thats going on the car .Any way here is some pics of what i did to mine might help you one way or the other












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    Pit Crew Decade Plus User MK1_Oz's Avatar

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    Re: Mk1 Escort Door Pillar Rust

    essyrwd I am a little confused. You appear to be replacing ONLY the outer section of the door pillar leaving an inner panel and hinges in place. That is a Mk1 Escort??

    My car is not made like that but rather has these pieces;

    This is the inner panel (you can see where I have cut to remove the outer section)


    These are the 2 bits that make up the outer panel. The thick rusty one is spot welded behind the outer panel and contains the hinges


    They fit together thus



    To me this is not what you show in your pictures.

    I have emailed both Hadrians and Expressed about some new outer panels (including the hinges) as mine is now swiss cheese and I am a little worried about the strength of it after I have re spot welded in a thousand places. I also bent the out panel substantially trying to pull the spots apart and may not be able to make it look nice again. Huge money though for replacement panels

    Anybody know if the Hadrian and Expressed panels look like mine? Is one supplier better than the other (can probably guess the answer)???
    1970 Mk1 Escort Tarmac Rally Car

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    World Champion Decade Plus User exboyracer's Avatar

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    Re: Mk1 Escort Door Pillar Rust

    Essyrwd's photos are correct and of a MK1 Escort, all he has done is remove the outer A post skin and left the hinge panel in place, thus you cannot see the inner A post skin in his photos.

    Your hinge panel should clean up nicely, they're thick steel and even mine was not badly corroded enough to require replacement.
    http://escort.accelerator.org
    1968 MK1 Escort 1300GT
    1969 'Big Wing' MK1 Escort
    1972 MK3 Cortina 1600XL
    1984 Sierra XR4i
    And other junk I don't like to talk about!

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    Pit Crew Decade Plus User MK1_Oz's Avatar

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    Re: Mk1 Escort Door Pillar Rust

    Now that you say that and when I look again it does look the same

    I started cleaning. Thick hinge panel will be fine. Thinking hard about the outer panel as it is very pitted inside. These cars dont appear to have much side impact strength anyway (see a few very scarey training videos at work of old cars vs new) so I need every bit of metal possible
    1970 Mk1 Escort Tarmac Rally Car

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    Bodger

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    Re: Mk1 Escort Door Pillar Rust

    "These cars dont appear to have much side impact strength"

    That's why your roll cage needs substantial side intrusion bars!
    People have been known then to remove those heavy intrusion bars from inside the standard door too (chasing weight).

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    Re: Mk1 Escort Door Pillar Rust

    When we cut up modern crashed cars at work you can see there are many layers in the A and B pillars. This metal is also of a higher grade/strength. Most modern cars also contain bars made of a boron/iron compond that is as tough as nails. The poor old Escort has 2 layers of thin tin

    I agree with your roll cage comment. My plan is to have a cage that keeps me as safe as possible - bugger the extra weight. I would also like to have it run into the engine compartment/to the front struts as the frontal impact protection on these cars is non-existant. The latest training vid we saw had a 20-25 year old car dropped from a hight onto its nose to simulate a 100km head on crash. They did the same with a new Commodare. The Commodore had minimal damage to the occupants area whereas the old car had the boot and bonnet on the drivers lap - that scared me!!!!!

    Is there a recognised design for a Mk1 Escort cage? I know that CAMS have plenty of design options in the regs but they are not Mk1 specific.
    1970 Mk1 Escort Tarmac Rally Car

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