stunning.
stunning.
Didn't get as much done as I wanted so but got the bottle of argon sorted so it was tack the tramp bar brackets to the axle and then remove it again for welding
Time to refit it for hopefully the last time
Next are the rear brakes, cosworth calipers being used so dressed and on
Next was to rebuild the calipers so full strip, blast, paint and Pistons seals all replaced
On putting the RS alloy back the calipers seemed to foul the inner rim, tried th7" Ronals and no problem so calipers will stay off until the wheels get refurbished
Next was to get the engine off the stand and onto the cradle so I could fit the flywheel, first job was to fit the sprigot ring
Next was the lightened flywheel curtesy of retro ford
Next was the dirt shield
Next was the clutch, which again curtesy of retro ford
Looking good
That's her dressed so happy with the way it turned out. Gearbox got cleaned up but I think she is going to be the weak link as she is just a standard type 9 out of a 2.0 now with the alloy RS bell housing. Will worry about it another day
Next it's the fuel tank. Nightmare with the thread pattern on the outlet, barious different references on the sites from 3/4 BSP, 3/4 UNF, none fitted so it was modify what I had and come up with something with an AN8 fitting
So started with this
Once removed looks like this, after all these years didn't realise they had a filter in the tank
Next plan was to cut the nut the nut off so the 3/4 tank fitting was flat and then weld on an AN8 fitting
Once done I cut the small pipe on the inlet side of the tank and drilled and tapped a 12mm hole for an inline filter, which made me smile as it came from a ford tractor. End result looks like this.
Dowty washer and then fitted and end result, just the dogs
Next it's clean the tank up ready for paint
End result
For the return I just drilled the fuel sender and fitted an AN6 fuel cell fitting
Well that's it for the next while, next will be fuel lines, brake lines and pedal box so let's see how that goes
Long time since I updated but for good reason, not a lot done. Keeping the classic look but bit of a hidden modern touch under the carpet in the form of dynamat so after going through all the effort of welding the tunnel in, blending the welds so had the factory look, painting the floor in dove grey to look like primer and the a bit of overspray in yellow I hide it all for a quieter ride
First a reminder, big tunnel
Tunnel cut out and bulkhead getting welded back in
Tunnel welded in and getting dressed
NOS seat box reinstated
Gearbox and engine trial fitted and raiser plate fitted
Now painted and looking much better
Time to start with the dynamat
Glad that's done as it's a pain in all the nooks and crannies
Next was the battery tray in the boot, she was yellow to start with
Needs to be black as the plan is to blend it in so it doesn't stick out like a sore thumb, black carpet will be in the boot so black tray will look better
Staying with the black and yellow theme, started to dress the underside of the bonnet
Wiring next, so will update later
wow, very nice build, how could i have missed this
Thanks Andy, easily missed as progress is slow but will get there one year
worth it in the end, no matter how long it takes
Very nice indeed what was the cost to get the lights chromed and what bond did you use please
Ashford Chroming at 220 quid for the pair, sealant was just white fish tank sealant
Can I ask where the catch tank is from?
Hexham and District Motorclub
Torques, good quality and not a bad price.
Wiring harness, where to start. Thought about getting a replacement made and a few to choose from, Alan at Premier wiring (gentleman and very helpful every time I spoke to him), rapitfit looms again sounds good but feedback varies so to heck with went with reworking my own loom
Where to start, original loom
Then the zetec loom, emerald ECU and focus st engine bay loom
Needed some help so it was a call to emerald and an engine bay harness provide which is easily married into the the original Mk2 harness
Trial fit that onto the engine just to make sure it's as easy as says on the tin
Great, now all the bits together on the floor. Main loom, rear loom, fuel pump wiring loom, replacement engine bay loom & battery cables as she will be in the boot
Next was the fuse box, plan is to change ceramic original fuse box for a more modern blade fuse box, replacement found and is a direct fit
Next, clean up all the connectors and marry the lot together
If anyone knows a way of getting the connectors looking good again, let me know and I will update later in the month
Where did u get the fuse box from cheers
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Got the replacement fuse box from auto electrics, quite a few places do them, you can also try car builder solutions
Thanks beerRS, stripped the harness of the tape, redid most of the spades and used heat shrink so they look tidy so now it's try the degrease
So what did I get done in the last few months, well no where near what I wanted due to spending time with the wee fellow over the festivities. Plans were to fit the dynamat to the the roof and fit the headliner once I changed the colour from putty to black, didnt get the dynamat installed but did manage to scrub the headliner and paint it black
Now with some paint applied. Did try the Dye supplied by AutoGlym but alas not what I expected as 2 cans and I could still see the putty colour so had some Halfords vinyl trim paint and it was great to apply and turned out smart
As I didn't get the dynamat finished, I could get the headliner installed and then the next job put on hold was installing the glass so hopefully next time
So what next, brakes. Have the Hydraulic Pedal Box, remote Servo thanks to VWJim and reservoir bottles so bottles fitted first
Next problem, bottles touch the bonnet when its closed
So its modify the bracket, lower it 10mm and sent it back of for poweder coating. What next, due to the holidays wont get the bracket back till January
What next, lets run some brake pipes
Job now at a stop as the plate that fixes to the bulk head is also still at the powder coaters.
Only job left to do is get the wheels refurbed and mated up with some tyres, first wheels before the refurb
Some good old good year eagle NCT 2s, 205s, bit wide but will probably go back to 185
Back from the the Wheel Specialist in Aberdeen who did a great job so delighted
Hopefully next time back in the garage the brakes will be done, dynamat finished, glass in and finally wiring harness in place but not going to hold my breath
Happy New Year to one all all when it comes
lovely car and lovely build at high quality ! I'm also thinking dynamatting my car. From what i hear it works like it should.
Thank you sir, your own build is a stunner and taking shape nicely and again quality built. Dynamat is good stuff and you need patience but worth it I am told
Beeeeeautiful. Bet you can't wait to get behind the wheel
You are right there. Done plenrty looking at at and imagining so looking forward to hearing it fire up in anger again
That's looking very smart - really clean, neat and tidy. Not sure why, but the mk2 RS2000 in always looks great in yellow!
Great job with the headliner by the way - I did a similar thing with a pair of putty coloured sunvisors and they turned out fab.
Thanks big fella, was looking at painting the headliner for a long time and glad I eventually got round it as it turned out spot on. Your own Mk1 must be nearly done as she has come on well since you got her back
making a cracking job of that donnie,its worth doing the archs and all the holes with the dynamat as a lot of noise is transfered in through them
Thanks for that and will do as the plan is to keep her as quiet as possible inside and loud as possible outside
What have I done this the last update, first more soundproofing with the dynamat extreme going on the roof
Once done it's time to refit the original soundproofing
Now ready for the headlining and as she was kept with boiler it was so easy to install as I could stretch it and fit a transit
Only problem was once in and looking at it closely I realised it was a bad by as it was from a left hooker so removed and replacement sourced, so more scrubbing / prepping and painting next time back
Next it's carry on dressing the engine with the exhaust going on next, retro Ford exhaust manifold now installed
So sun was out for a wee while so far chucked out for its annual outing, shame it's just not under its own steam
Still not happy with the rechromed inner headlights so going to remove the lenses again and see if I can polish up the chrome and see if it will make a difference, also got a spare set chrome sprayed so will try that option as well and see which one looks the best
Next after looking at it for months finally got my finger out so next it's get the engine into the bay
Up and over time
Looking good if I must say so myself
So with the engine in the bay I thought I would try something different and see if I could do something different but alas where do you stop. Next up carbon dipping
Rocker cover
Cam belt Cover and windscreen washer bottle as I couldn't get it clean
Now it's time to stick it back in the corner of the garage and cover her up till the next time
Next task, engine back out, finish the wiring as I now have trial fitted the loom so all lengths sorted and ready for loom tape, fit pedal box and remote servo so I can refit the bulkhead pad, reservoir bottles, connect brake lines to the bulkhead plate and alas all brake lines done
That's looking bloody ace. I like the dedication to sticking with the black and yellow theme in the engine bay!
Fantastic build. Great read/thread. Going to be a stunning RS. Too good to use?? Lets hope not!! Superb👍👍
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Thanks boys and don't worry, built for using and not a trailer queen
Stunner, that will be a lovely thing to drive.
Thats bloody lovely mate, that would be a cracking daily driver!
Thanks Erik and Dave, she is taking shape slowly but surely, plan is to have her ready for next summer and then give her a good using
How do you find the diff clearance with the Atlas and std diff tunnel?
Looks as if there is plenty room with no issues but will have to wait till it's on the road before I can answer that one with confidence
Been planning fitting an Atlas in mine but im unsure if i'll need a bigger diff tunnel as its pretty low, let me know how you get on.
great read this , well done
This is under full drop on the wheels-free ramp, so take the amount of space shown with a pinch of salt!:
P1070409-.JPG
P1070410-.JPG
P1070426-.JPG
Any use?
I can probably get some better pictures including measuring the top clearance to the diff tunnel this weekend if it would help; the car is pretty low now, so it should give you a good idea.
This is under full drop on the wheels-free ramp, so take the amount of space shown with a pinch of salt!:
Attachment 80918
Attachment 80919
Attachment 80920
Any use?
I can probably get some better pictures including measuring the top clearance to the diff tunnel this weekend if it would help; the car is pretty low now, so it should give you a good idea.
This is comeing along brilliant mate looks fantastic
Cheers fella, getting there really slowly but no rush
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