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Thread: quick mk2 project (zetec hopefully)

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    quick mk2 project (zetec hopefully)

    quick , yea right
    ive had this for about 6 months now but wanted to get a head start
    then my phone packed in and i lost a load of pics (any k800 lockup experts?)

    anyway its time i posted so here we go. i will be trying to sort it in stages , front, back then engine then body . maybe

    its a 4 door GL was blue then gold amongs others. now going strato silver.

    ok, part one. the front end .......

    bulkhead had rotted inc the front of bubble and top of tunnel.



    all cut out


    made a new tunnel front. i had thoughts to make space for the std zetec thermostat housing but changed my mind.





    patched.



    front floor patched in as well

    Last edited by alladdin; 29-04-2010 at 22:52.

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    Re: quick m2 project (zetec hopefully)

    i also wanted to swap to large strut top size as i have billys to go on.
    i also had a set of mk2 big hole strut top repair panels to hand (20 yrs to hand )



    jigsaw is best but i broke blade so used grinder and 1mm disc





    Last edited by alladdin; 29-04-2010 at 23:00.

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    Re: quick m2 project (zetec hopefully)

    gave the under wing area some shultz to make it more presentable.





    paint next then.

    oops pic size ,,,,,,,,,,,,,,,,, sorted.




    happy now perky
    Last edited by alladdin; 29-04-2010 at 23:10.

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    Re: quick m2 project (zetec hopefully)

    nice one! lookin good, when are you hopin to have it done by?

    "if its too loud, you're too old!"

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    Part of the furniture Decade Plus User trig's Avatar

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    Re: quick m2 project (zetec hopefully)

    Fook me about time you started your own thread

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    Re: quick m2 project (zetec hopefully)

    Quote Originally Posted by alladdin View Post
    i also wanted to swap to large strut top size as i have billys to go on.
    i also had a set of mk2 big hole strut top repair panels to hand (20 yrs to hand )



    jigsaw is best but i broke blade so used grinder and 1mm disc



    Nice number stamping

    Keep the piccies comming

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    Re: quick m2 project (zetec hopefully)

    yes nice job , thanks for that and the top plate i cut down fits better than it looks !

    well its not a show car build so its onto some painting. garage was like a dusty cold tip, gun was unused for years, painter was errr unskilled (me ) so all in all it should be a breeze
    i asked trig for some advice before the final coats and he mentioned something called masking so..... being a pro i threw an old curtain over the screen




    primer on




    and after a quick scotchbrite and a little silver 2k the bays looking better




    all considered im more than happy with it

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    Racer 4drmatt's Avatar

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    Re: quick m2 project (zetec hopefully)

    people keep mentioning that masking thing to me?!?!

    looking good silver is a great colour for an escort

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    Re: quick m2 project (zetec hopefully)

    lookin good mate!!

    "if its too loud, you're too old!"

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    Re: quick m2 project (zetec hopefully)

    I agree Escorts look well in silver

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    Re: quick m2 project (zetec hopefully)

    i moved onto the back today

    its had arches in the past but the old ones were inside. i spent a few loverly hours cutting/wire brushing the old rusty lips out. my plan is to put a strip from inner to outer arch to rejoin them and then roll (ok hammer) the lip back . will get some pics over the weekend hopefully.

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    Re: quick m2 project (zetec hopefully)

    At last, be done in afew weeks so get it down for Trigs trackday

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    Re: quick m2 project (zetec hopefully)

    Looking good, like the silver on the bay!

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    Re: quick m2 project (zetec hopefully)

    Cheers guys

    another few hrs yesterday cutting/cleaning and a few today sweeping up but no real progress
    Last edited by alladdin; 02-05-2010 at 16:59.

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    Re: quick m2 project (zetec hopefully)

    well it seems that all the crud in the rear arches got the better of my lungs at the moment im restricted to dipping rusty bits in a very grotty barrel

    i did get some batteries for my old camera tho so at least some rust pics this is far as i got before swallowing 1/2 an old arch












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    Re: quick m2 project (zetec hopefully)

    slipping down the pages at a worrying rate !

    not a massive update but got the inner arches sorted and moved onto the spare well (done ) and the tank well (in progress.)





    i rolled the arch back (with a mallet ) before getting the seam sealer on





    onto the tank well



    in case anyone thought it was all stuck together with my new seam sealer friend



    not done to show standards but its a user so hopefully it should all see a few years

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    Re: quick m2 project (zetec hopefully)

    got the tank well finished.







    patched the small hole and all painted .

    now it just needs some shultz and the rear end is done

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    Racer Decade Plus User PERKY's Avatar
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    Re: quick m2 project (zetec hopefully)

    Getting there mate

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    Re: quick m2 project (zetec hopefully)

    Good work there.

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    Re: quick m2 project (zetec hopefully)

    still plodding along

    all the welding repairs now finished so some boring shots of the shutzed underfloor to pull this thread up







    and before i got spraying i fitted this usefull thing off the garage wall





    well it is a 4door

    painted inside with wilko black



    now to put some wheels back on. oh, and that wiring might want tidying

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    Re: quick m2 project (zetec hopefully)

    first part of the suspension build was to sort some anti roll bar mounts. the mk1 twin cam antiroll bar adds caster from the shape of the bar itself and also via an extra set of holes in the brackets moving the bar forward by 20mm ish ( i will put some pics and measurements on soon), so since i had some old double width brackets i thought i would mod them to add some caster to my setup.
    this is before cutting, ive added some spacers to accept the double width rubbers



    base cut out of bracket and front 20mm removed



    these 3 show it back together with a 20mm strip/infill at the rear







    wilko black



    painted some other bits.


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    Re: quick m2 project (zetec hopefully)

    got the xmember and arb / tca 's setup all fitted



    pics not the best but you can see here the tca being pulled forward by the modded brackets.



    started to degrease some big bits , i used a "parafin gun" thingy to spray with degreaser at 100 psi which worked fairly well



    then made a jig setup from a genuine rs axle to locate the new tramp brackets onto a standard axle correctly.
    i know its not vital but it helps to make the axle / tramp setup interchangable with any rs type shell or easier to replace.







    now today was a very special day
    today i got 2 of the kids to help with the escort for the first time (ok, they were bored and i paid them)
    anyway they got busy painting....... i left them to it ......... i came back .....



    shiney brakes!

    quick clean up of the shoes and axles finished, if a little .... errrrr... gritty....



    box quickly follows


    all in all a decent job

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    Part of the furniture Decade Plus User Ratters's Avatar

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    Re: quick m2 project (zetec hopefully)

    nice work

    you could sell some of those shiny brake shoes to some of the concours guys

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    Re: quick m2 project (zetec hopefully)

    Whats the rad from?

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    Re: quick m2 project (zetec hopefully)


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    Re: quick m2 project (zetec hopefully)

    Looking good bud

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    Re: quick m2 project (zetec hopefully)

    just a very quick update , well an excuse to drag it up a page more like

    managed to get the front struts built up and fitted, i made these up a good while back ready for the mk1 but hey ho






    just some steering required for the front then,,,,,

    and my mission this week is to get the axle back on.

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    Part of the furniture Decade Plus User trig's Avatar

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    Re: quick m2 project (zetec hopefully)

    Looking good bud when's the engine going in and do you have every thing to fit it and run it ???

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    Re: quick m2 project (zetec hopefully)

    as soon as its rolling and the front brake lines are in i can start fitting the engine. the only thing i know for sure i need is an exhaust manifold............. but who knows when i start fitting the bits ive collected

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    Re: quick m2 project (zetec hopefully)

    would have fitted the axle today but i thought i would be flash and use a 2" lowering kit i have "in stock"

    what the hell are they supposed to fit ? they dont fit escort axles , well this one dont

    it comes with shim/spacers which either fit the top of the alloy block nice but dont fit into axle saddle as they are too small /sloppy

    or fit over axle "nipple but dont seat properlyonto spring and dont wedge fully into bottom of ally block

    so plan is to use the thin rubber saddles as the tit on top of alloy block sits nice into top rubber (to axle saddle)
    and then make some new rings to fit the blocks tight/central onto spring . the other rubber will then be used to fit the bottom saddle as normal......

    any comments
    Last edited by alladdin; 16-08-2010 at 21:06.

  31. #31
    Racer Decade Plus User PERKY's Avatar
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    Re: quick m2 project (zetec hopefully)

    I remember doing them on my old mk2, they were a shocking fit too. think my boss turned some on the lathe for me that fitted a treat.
    Any photos then?

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    Re: quick m2 project (zetec hopefully)

    heres the spacers, the 2 i made today are thicker (no reason) and have a bigger counterbore to sit over the spring tit.



    this is it fitted into the bottom of the lowering block



    spacer over spring tit, the original sat up 2mm off spring. i could have filed it to fit tbh.




    i will post some more later of the assembly . it may help someone ................. or i might be doing it all wrong
    Last edited by alladdin; 17-08-2010 at 18:08.

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    Re: quick m2 project (zetec hopefully)

    this is the top rubber in the upper saddle, the indent is the inside of the tophat bit that locates into the axle saddle/spring mount. the pip on the top of the lowering block locates into this indent.


    this is it assembled



    bottom rubber in place , it also has an indent that locates onto bottom of spring "tit" and a "topHAT" which goes into the hole in bottom shock mnt plate



    full assembly nipped up .



    i wont tighten it untill i fit the tramp bars. the tramp bar kits a rallydesign item, they have sold these for ages so they fit like a glove by now,

    dont they ?

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    Re: quick m2 project (zetec hopefully)

    must be one of beadles old gloves then

    like most things they dont seem to fit

    when put where im guessing they should go the top fold is ablut 10mm short of going over the chassis rail anyone else had this ? am i missing something ?






    and after getting the lowering blocks to fit nicely it seems they may be a little low with my nice soft old springs, this is with axle jacked to just lift wheels. no shocks, 13mm bump stop clearance and i can just get my fingers between arch and tyre (arches are rolled)............


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    Re: quick m2 project (zetec hopefully)

    Throw the rubbers around the blocks in the bin, that will get you a bit more clearance and stop the axle tramping still as the block/axle can wind up into the rubber. Is the arch rolled/hammered right flat to the outer lip? if so you need wheels with a better offset!

    And as for the shell brackets, they look about right! Iirc i cut mine on that fold and welded them up with a big gap, either that or straightened the fold and then welded the brackets in and folded it back where i could

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    Re: quick m2 project (zetec hopefully)

    The chassis rail needs to be drilled so the bracket will sit up to the side of the rail. As you will see when you hold it on the nut for the tramp bar bolt hits the chassis, thats what you need to drill the hole for.

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    Re: quick m2 project (zetec hopefully)

    i realise the hole is needed for the chassis to sit flush to bracket, tbh it also seems to want 15mm to move forward to fit the arms as ive already mounted the axyle brkts (see above). pics later.

    dave, i wanted to keep the rubbers to minimise road noise as its a comfy more door. arches are pretty well flat and the clearance is i think its mainly the soft springs.

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    Re: quick m2 project (zetec hopefully)

    ground a notch to go over the curved lip thats on the original double skin bit. also hammered the chassis side fold flat , i should have cut it off like dangerous did.



    so now fits like this, not flat to chass rail yet despite looking like it as its still 10mm off due to the hole still not cut for the nut. part of it is in contact tho. see last pic.



    looks like i need to cut back along the marked line to allow the nut to go into hole (still not cut yet) in chassis rail.



    i need to check the dimension of the chassis hole ctr rearward from the double skin lip for eg. on a std rs mk2. before progressing
    anyone got it or can measure it ????????

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    Re: quick m2 project (zetec hopefully)

    I vaguely remembering having to chop down that other bit as of course where the spring hanger is the metal is around 2mm so you need to chop that much out the front part of the mount too!

    I have searched the archives on my computer and dug these up, i wasnt going mad earlier when i couldnt decide what way i did the lip....thats because i did it both ways One side bent and refolded when welded and the other side cut and filled the gap with weld





    As for the hole, i just got it where it looked right and stuck a pencil through the open hole and the nut and drew however big a circle i could and then starrett cuttered the hole, with the notch for the flick on the back of the spring hanger right in that corner of the mount...but then i was on rose jointed location arms so it didnt matter too much. Also with regards to the comfyness of the rubbers round the block, thats what the spring bushes are for, bin the ones round the blocks you wont notice the difference in noise and probably will notice less slop/tramp
    Last edited by dangerousdave; 19-08-2010 at 21:49.

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    Re: quick m2 project (zetec hopefully)

    cheers dave, the pics look exactly how i wanted to fit them. problem is that i welded the axle brackets 1st thinking of interchangability with std axle and now i think the arms are going to push the boxes forward more (arms are same as std ive checked) which makes them awkward to fit without flattening the curled lip. pics of std boxes look like the bolt is where yours is more or less...................

    and i think 2" drop on these springs will be 2 low on the roads in my area !

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