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Thread: Mk2 RS200 Story so far

  1. #41
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    Re: Mk2 RS200 Story so far

    stunning.

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    Re: Mk2 RS200 Story so far

    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

  4. #43
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    Re: Mk2 RS200 Story so far

    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

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  6. #44
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    Re: Mk2 RS200 Story so far

    wow, very nice build, how could i have missed this

  7. #45
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    Re: Mk2 RS200 Story so far

    Thanks Andy, easily missed as progress is slow but will get there one year

  8. #46
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    Re: Mk2 RS200 Story so far

    worth it in the end, no matter how long it takes

  9. #47
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    Re: Mk2 RS200 Story so far

    Very nice indeed what was the cost to get the lights chromed and what bond did you use please

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  11. #48
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    Re: Mk2 RS200 Story so far

    Ashford Chroming at 220 quid for the pair, sealant was just white fish tank sealant

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    Racer Decade Plus User mexicotait's Avatar

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    Re: Mk2 RS200 Story so far

    Can I ask where the catch tank is from?
    Hexham and District Motorclub

  14. #50
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    Re: Mk2 RS200 Story so far

    Torques, good quality and not a bad price.

  15. #51
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    Re: Mk2 RS200 Story so far

    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

  16. #52
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    Mk2 RS200 Story so far

    Where did u get the fuse box from cheers


    Sent from my iPhone using Tapatalk

  17. #53
    Mechanic beeRS's Avatar

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    Re: Mk2 RS200 Story so far

    Quote Originally Posted by donnie View Post
    If anyone knows a way of getting the connectors looking good again, let me know and I will update later in the month
    I sorted my connectors by unclipping the metal spade connectors within, and then cleaning the white plastic parts by soaking in a de-greaser.

  18. #54
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    Re: Mk2 RS200 Story so far

    Got the replacement fuse box from auto electrics, quite a few places do them, you can also try car builder solutions

  19. #55
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    Re: Mk2 RS200 Story so far

    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

  20. #56
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    Re: Mk2 RS200 Story so far

    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

  21. #57
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    Re: Mk2 RS200 Story so far

    lovely car and lovely build at high quality ! I'm also thinking dynamatting my car. From what i hear it works like it should.

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  23. #58
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    Re: Mk2 RS200 Story so far

    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

  24. #59
    Mechanic davemk1's Avatar

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    Re: Mk2 RS200 Story so far

    Beeeeeautiful. Bet you can't wait to get behind the wheel

  25. #60
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    Re: Mk2 RS200 Story so far

    You are right there. Done plenrty looking at at and imagining so looking forward to hearing it fire up in anger again

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    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Mk2 RS200 Story so far

    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.

  27. #62
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    Re: Mk2 RS200 Story so far

    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

  28. #63
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    Re: Mk2 RS200 Story so far

    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

  29. #64
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    Re: Mk2 RS200 Story so far

    Thanks for that and will do as the plan is to keep her as quiet as possible inside and loud as possible outside

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    Re: Mk2 RS200 Story so far

    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

  31. #66
    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Mk2 RS200 Story so far

    That's looking bloody ace. I like the dedication to sticking with the black and yellow theme in the engine bay!

  32. #67
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    Fantastic build. Great read/thread. Going to be a stunning RS. Too good to use?? Lets hope not!! Superb👍👍

    Sent from my SM-G900F using Tapatalk

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    Re: Mk2 RS200 Story so far

    Thanks boys and don't worry, built for using and not a trailer queen

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    Re: Mk2 RS200 Story so far

    Stunner, that will be a lovely thing to drive.

  36. #70
    Mechanic DANGERDAVE80's Avatar

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    Re: Mk2 RS200 Story so far

    Thats bloody lovely mate, that would be a cracking daily driver!

  37. #71
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    Re: Mk2 RS200 Story so far

    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

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    Re: Mk2 RS200 Story so far

    How do you find the diff clearance with the Atlas and std diff tunnel?

  39. #73
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    Re: Mk2 RS200 Story so far

    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

  40. #74
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    Re: Mk2 RS200 Story so far

    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.

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    Pit Crew Decade Plus User MegatronUK's Avatar

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    Re: Mk2 RS200 Story so far

    Quote Originally Posted by Erikmex View Post
    How do you find the diff clearance with the Atlas and std diff tunnel?
    I found there was plenty of space on mine, though I did angle the nose down a couple of degrees. Not masses of space, of course.

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  43. #76
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    Re: Mk2 RS200 Story so far

    great read this , well done

  44. #77
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    Re: Mk2 RS200 Story so far

    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.

  45. #78
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    Re: Mk2 RS200 Story so far

    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.

  46. #79
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    Re: Mk2 RS200 Story so far

    This is comeing along brilliant mate looks fantastic

  47. #80
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    Re: Mk2 RS200 Story so far

    Cheers fella, getting there really slowly but no rush

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