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Thread: Road Rally MK2 4 Door (XE powered)

  1. #121
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Update time. Well the car is back in bits and there is plenty of work to be done. It started when I got fed up of the diff not locking as quickly as I wanted, so the axle came off for a strip down. I was under the impression it was a genuine motorsport zf diff, but it turned out to be a capri diff with motorsport plates. Upon inspection all the plates looked good and the preload was still at the recommended setting. After speaking to a few axle builders I decided to sell the zf and ordered a brand new gripper with 30/60 ramps as they were very reasonably priced and recommended. I've just had the new diff built into the casing and it's now sitting in the garage ready for the shafts and new bearings to go in.



    While the axle was off I decided I wanted to repair a few holes in the boot, so I ordered a welder. I removed the paint with the wire brush attachment to reveal the full extent of the rust in the rear. I also discovered that the replacement wheel arches had been welded over existing rot, so they had to come off to be re done.

    What was left







    So out with the tank and fuel pump ready for welding. John (freddy68) very kindly come over for a few hours to get me started on the welding, and we managed to get a wheel arch done.
    I'm now starting to repair the rest of the boot area but it's very slow progress at the moment as I'm starting to loose enthusiasm with the nice weather we have been getting.




  2. #122
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    Re: Road Rally MK2 4 Door (XE powered)

    I got a gripper in my atlas good bit ov kit at a low price

  3. #123
    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    You'll have to get stuck into the other side with out me now

  4. #124
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Trust you john to come over and do the easy side lol, great help though.

    A little more welding done



    And the axle is back and built up


  5. #125
    Mechanic MCURZON's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Axle looks lush!

  6. #126
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    A few repairs to the passenger side rear tub





    Starting on the drivers side rear now with a new outer and inner arch




  7. #127
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    A little bit more done on the weekend



    Last edited by lukem30; 04-08-2014 at 22:38.

  8. #128
    Pole Position Decade Plus User freddy686868's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Still going but looking lovely you'll be teaching me a thing or two on the welder soon.

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  10. #129
    Tyre Kicker

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    Re: Road Rally MK2 4 Door (XE powered)

    Epic welding dude

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  12. #130
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    Re: Road Rally MK2 4 Door (XE powered)

    loving this thread, would love to see car, plan on redtop with inj pick your brains lol, nice to see car in action! Nathan.

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  14. #131
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Cheers, your welcome to come up for a look, I didn't do the convertion myself but you can see how it all fits. Probably won't be in action for a while, plenty more welding to sort

  15. #132
    Bodger

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    Re: Road Rally MK2 4 Door (XE powered)

    many thanks been there lol, lucky just floors etc but all time consuming! who does your r/r?

  16. #133
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    You should get a build thread up on here. Vince mosely @ Moselys rolling road has done all the mapping, bit of a trek, but very happy with it now.

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  18. #134
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Had some time this weekend to have a go at the car again,

    Last bit of welding on the read end





    Rear tow eye welded in place


    Inside the boot has been seam sealed and primed




    And I've stone chipped up to the floor pan

    Last edited by lukem30; 21-09-2014 at 21:56.

  19. #135
    Mechanic danknight72's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Looking good luke

  20. #136
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    Re: Road Rally MK2 4 Door (XE powered)

    something are easyer with a 4 door :-)

  21. #137
    Racer Decade Plus User mexicotait's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    What stone chip pain did you use ?
    Hexham and District Motorclub

  22. #138
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    Re: Road Rally MK2 4 Door (XE powered)

    Nice work

  23. #139
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Back in the garage again after a fair while off. First on list was to repair the 2 rear chassis rails.

    Cut out the rot and replaced the inner skin with new


    Then the outer


    Next was the double passenger sill to come off, the first one


    What was underneath


    And the second one


    Which left me with a crusty inner sill to repair


    Out with the old


    And in with some new metal



  24. #140
    Racer Decade Plus User evans2822's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Nice repair work

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  26. #141
    Mechanic danknight72's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Well in mate

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  28. #142
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Today's effort




    Both front doors to repair next

  29. #143
    Mechanic azz259's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Looking good, how much work you got left?

  30. #144
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Quote Originally Posted by azz259 View Post
    Looking good, how much work you got left?
    Just finished up the welding today, onto bodywork next so hopefully won't be too much longer. I think I'm going to leave the engine bay until another time as I want to get the car back on the road.

  31. #145
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Hopefully this is the last of the welding until I get round to getting the engine out to paint the bay.
    I repaired the drivers front door with a few small patches, but the passenger door was too far gone, so I picked up a cheap replacement that only needed a minor repair which I've also now sorted.



    And the last bit to sort was to weld up scuttle.






    I have also purchased a fiberglass boot and bonnet, so I made some backing plates ready to fit the boot to the original hinges.

    Last edited by lukem30; 08-12-2014 at 00:33.

  32. #146
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    Re: Road Rally MK2 4 Door (XE powered)

    top class repairs there and great build !!!

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  34. #147
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    Re: Road Rally MK2 4 Door (XE powered)

    Great job Wy did you weld the scuttle panel ?

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  36. #148
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    I've got a heater out of a classic mini, so all the cold air from outside was rushing in throught the big hole where the original ford heater collected air, so was making my feet cold. I've seen a few people fit carbon scuttle blanks, but the welder was there ready to go.

  37. #149
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    Re: Road Rally MK2 4 Door (XE powered)

    Nice welding work, but where is your heater going to pick up the fresh air from now? It will be like running in recirc mode. It will mist up. Or do you plan to bring it in from elsewhere?

  38. #150
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    I've been running with it taped up for the last year or so and its been fine, it just looks a bit crappy with a load of silver tape over it so I thought I would do a propper job.

  39. #151
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Finally, some paint





  40. #152
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Last of the garage until the new year. I've got a few little runs so I think I'll rub down and repaint that area. My first go at painting so I'm sure I'll have a few hiccups along the way.





  41. #153
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    Re: Road Rally MK2 4 Door (XE powered)

    What a nice first go at painting mate! Cheap to!

    Mine is also just like that at the moment.

    Cheers,

    Mário Santos.

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  43. #154
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    its hard to coax myself in the garage in this cold weather but I managed to get a little further forward.

    Put some paint on the roof, bootlid and back panel, then filled and shaped the rear arches and scuttle area.




  44. #155
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    It's been hard work learning to paint in the cold weather but it's finally painted. It not the best but good enough for the lanes.

    All door shuts painted


    Managed to pick up a cheap heater as I was finishing off


    Side windows re-fitted with safety film fitted ready for logbook


    Starting to line up the bonnet properly and fit the aero catches



  45. #156
    Pit Crew Decade Plus User para144's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Looks great Luke, top job!

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  47. #157
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Cheers mike. Have you got anything planned, haven't seen the car out for a long time

  48. #158
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    Re: Road Rally MK2 4 Door (XE powered)

    Looking good

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  50. #159
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    Re: Road Rally MK2 4 Door (XE powered)

    Quote Originally Posted by lukem30 View Post
    Cheers mike. Have you got anything planned, haven't seen the car out for a long time
    After doing Flanders last year I was travelling a lot for work. Also needed to llet the bank balance recover!
    Looking at doing an event or two soon. I didn't enter the championship this year so I have some flexibility.

    Heading for the stages then?

  51. #160
    Spanner Monkey lukem30's Avatar

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    Re: Road Rally MK2 4 Door (XE powered)

    Quote Originally Posted by para144 View Post
    After doing Flanders last year I was travelling a lot for work. Also needed to llet the bank balance recover!
    Looking at doing an event or two soon. I didn't enter the championship this year so I have some flexibility.

    Heading for the stages then?
    Tbh I think it's more fun to do the events you fancy rather than commit to a championship. I havnt seen your new car yet. I'm hoping to get mine logbooked and do my bars this year, then maybe get out on the stages next year.

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