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Thread: Group 4 Mk2 total rebuild/Restoration!

  1. #1
    Spanner Monkey

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    Group 4 Mk2 total rebuild/Restoration!

    Ok I have been on here for a while and have finally got round to sorting out a build log for my car!!
    I have had it for 2 years already but with the arrival of my daughter and moving house time is at a premium, I am hoping once we have moved that I can have a little more time to get on with it!!
    Any help or advice is appreciated!!

    It was a decent spec rally car in the first place but when I brought it it needed some tidying and so the saga begins!! I decided to go for a full strip down and build it back up from a bare shell.
    These Pictures are as I got it -

    As Brought.JPG

    Front leg.JPG

    Inside.JPG

    Engine Bay.JPG

    Rear Axle.JPG

    And these are some of the strip down ones -

    DSCF3238.JPG

    DSCF3241.JPG

    DSCF3243.JPG

    DSCF3392.JPG

    DSCF3394.JPG

    It has been for a good sand blasting and a few more bits have appeared that need attention, I will post more as I go!!

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    Bodger

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Yeah looks like you're gonna be warming up your grinder and MIG. Good luck with the resto. I'm in the same boat as you. ;-)

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    I support TS Decade Plus User
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    Re: Group 4 Mk2 total rebuild/Restoration!

    Looking like a good project. I'd be interested to see what it looked like after the sand blasting.

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    Spanner Monkey

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Thanks...the grinder has already been out!!! I will get some pictures up of it after blasting...to be honest the were only a couple of areas that I hadn't already found and these had been filled so they looked fine!!!

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    Spanner Monkey

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Right...here she is after blasting and a little tickle with the grinder to make a start on panel removal!!

    DSCF5353.JPG

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    DSCF5358.JPG

    DSCF5361.JPG

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    DSCN0379.JPG

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    DSCN0384.JPG

    DSCN0385.JPG

    As you can see there is a little more rot and someone has welded the panhard mount back on badly. This is not really a problem as I am going for Watts linkage to its coming off anyway! There is some plating in the boot floor that needs attention but I may just make a new floor piece to go in there and get rid of the whole bit!

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    Pit Crew

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Wot are you going to do keep it as a rally car

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    Spanner Monkey

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Yeah its staying a rally car and being upgraded as I go. It will have a full weld in safety devices cage and some more trick bits when I get the shell welded up. I am going to be building a redtop to go into it with a type 9 tran-x dog box and a semi floating atlas with watts linkage.

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    TURBOSPORT SPONSOR Turbosport Sponsor TJM's Avatar

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Hello

    I have full range of panels available if you need any with Turbosport 10% discount.

    Regards
    Tim
    TJ Motorsport
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    http://www.tjmotorsport.co.uk
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    Spanner Monkey redhf's Avatar

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    Group 4 Mk2 total rebuild/Restoration!

    Do you want to sell the sd cage that was in it?

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    Spanner Monkey

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Tim,
    I have already brought all the panels from yourself!! Top price and service Thanks.

    Sorry but the original cage was sold a few months ago.

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    Spanner Monkey

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Right, I have not had a great deal of time to do anything but have managed one day!! Moving house and children have taken over!!

    Still...got the drivers side floor pans cut out ready for new ones to go in and thats about it!! Hopefully I will get a bit more time after the house stuff is done!!

    IMG_1050.PNG

    IMG_1051.PNG

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    Pit Crew Decade Plus User Huxley's Avatar

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    Re: Group 4 Mk2 total rebuild/Restoration!

    I have some rear seat four link reinforcing plates if you need some for you build

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    Spanner Monkey

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Hux,

    Do you mean the ones that go across the car over the tunnel? If so I already have a pair thanks!

    Just need some time to get things underway and it will move along nicely! I have to re-roof my garage in the new year and then the car will be moving into the garage so I can spend more time on it!!

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    Pit Crew Decade Plus User Huxley's Avatar

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Ok no probs

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    Spanner Monkey

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Wow......have not posted on my thread for a long while!! The car is a lot further on than this now, I will post some pictures when I get a chance. Anyone got any clues how to resize them on you phone direct to here as they are all on my phone not my PC??!!

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    Spanner Monkey

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    Group 4 Mk2 total rebuild/Restoration!

    Ok so once I had moved house and reroofed the garage I moved the car up to mine and then I could crack on with it! I managed to cut out and replace all the offending rusty panels or parts! Replaced more than I thought I would but figured I wanted to do it right first time and not have to come back to it later when it was all painted!

    Sent from my SM-G930F using Tapatalk

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    Group 4 Mk2 total rebuild/Restoration!

    These pictures are all from 2015 so I have a fair few more to post to catch up on the build!

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    Group 4 Mk2 total rebuild/Restoration!

    Moving into 2016......decided to replace the whole front inner wing and front panels as the old ones were in a shit state!

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    Spanner Monkey

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    Group 4 Mk2 total rebuild/Restoration!

    The scrap run after cutting floors etc out!


    Front panel and nearside floors replaced! Plus exhaust tunnel. Decided to have 2 exhaust tunnels so that if I change engines in the future and the exhaust is on the other side the tunnel is already there!
    Also the gearbox has now changed from a tran-x SL72 to a Drenth dg400!

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    Group 4 Mk2 total rebuild/Restoration!



    Nearside sill fitting.



    Seat rails finished on both sides and the harness mounts welded in place.



    New chassis rails





    Fitting large rear tubs!

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    Group 4 Mk2 total rebuild/Restoration!

    Removing the boot floor and rear panel





    Welding in threaded books for the towing eyes



    Finished boot outer



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    Group 4 Mk2 total rebuild/Restoration!

    New flat boot floor all made and installed!




    Fitting the tank base


    Trying the axle



    Fitting watts towers





    And the boot floor strengthing bars for the towers



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    Group 4 Mk2 total rebuild/Restoration!

    Roll cage fitting! Lots of time spent making sure It's all fitted correctly










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    Group 4 Mk2 total rebuild/Restoration!

    More Roll cage fitting







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    Group 4 Mk2 total rebuild/Restoration!

    Fitting the engine block ready the make the chassis mounts and sort the gearbox mounting




    That's most of my new gearbox cover cut away then!



    Carbon parts and mounting the upright handbrake.



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    Group 4 Mk2 total rebuild/Restoration!

    Finished engine mounts



    Fuel lines and cables routed



    Exhaust fitted and modified to fit down the tunnels




    Rear arches fitted and finished






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  29. #27
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    Group 4 Mk2 total rebuild/Restoration!

    Corsa c column modified and mated to escort top and bottom




    Exhaust made and welded up






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    Spanner Monkey

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    Group 4 Mk2 total rebuild/Restoration!

    Dry Sump tank mount under the bonnet




    Oil filter mounted



    Oil cooler mounted and radiator





    Fitting the front wings and front splitter







    Fitting the bulkhead and the new harness bar



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  31. #29
    Racer Decade Plus User mexicotait's Avatar

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Great job you are doing so far

    Did you make or buy the reservoir bottle mounts?
    Hexham and District Motorclub

  32. #30
    Spanner Monkey

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Looking well, great job

  33. #31
    Racer

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    Re: Group 4 Mk2 total rebuild/Restoration!

    http://uploads.turbosport.co.uk/getr...4d00cf5a08.jpg

    Those seat bars are a shame - lot of work to include the 'frenched in' exhaust tunnels and you still ended up with a dropped exhaust. Did you need to box the bars seeing as once mounted, the seats rarely have to move?

  34. #32
    I support TS Turbosport Subscriber rallyrob's Avatar

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Quote Originally Posted by katana View Post

    Those seat bars are a shame - lot of work to include the 'frenched in' exhaust tunnels and you still ended up with a dropped exhaust. Did you need to box the bars seeing as once mounted, the seats rarely have to move?

    Funny that I thought exactly the same thing. All that work on the exhaust tunnel was kind of wasted...


    Having said that, still some very nice work going on there.


    Nice job with the Corsa C column too...
    Last edited by rallyrob; 13-06-2019 at 12:21.

  35. #33
    Spanner Monkey

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    Group 4 Mk2 total rebuild/Restoration!

    Quote Originally Posted by mexicotait View Post
    Great job you are doing so far

    Did you make or buy the reservoir bottle mounts?
    I made the mount. Not sure if you can get them made or not!

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  36. #34
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    Group 4 Mk2 total rebuild/Restoration!

    Thanks for the replies, the steering column was a bit of work but pleased with how it has turned out.
    If I did the seat mounts again i would change how the inners were mounted so I didn't have the box as I do agree it is a pain to have done the tunnels although the exhaust is still inside the chassis rail height.

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    Group 4 Mk2 total rebuild/Restoration!

    Fitting the underside floor protection



    Removing the paint off the roof panel.......8 layers! Serverel different colours!



    And the doors! Loads of filler in here!





    Masked up and tinted raptor added to the underside







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    Group 4 Mk2 total rebuild/Restoration!

    Inside in high build primer



    Then in gun metal grey





    Outside primed



    And then finished in gentian blue





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  39. #37
    Spanner Monkey

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    Group 4 Mk2 total rebuild/Restoration!

    Really happy with the paint finish considering it was done in my garage and I have never sprayed a whole car, let alone a Roll caged interior before! Now I can get on with building all the mechanical stuff starting with the axle!

    ZF diff rebuild Inc boring out to fit 18 spline side gears forcthe heavy duty quaife shafts



    Axle build









    Fitting it to the car





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  40. #38
    Spanner Monkey

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    Group 4 Mk2 total rebuild/Restoration!

    Rear lights and bumper fitted, home made carbon fibre inner lights as the old ones were shot, added LEDs for all rear lights!



    Carbon fuel pump mount



    Fuel lines installed









    Carbon upright handbrake and switch gear.



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  41. #39
    Mechanic beeRS's Avatar

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Epic work. Great to see it all coming together now. What is that 'tinted raptor' used on the underside?

  42. #40
    Bodger

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    Re: Group 4 Mk2 total rebuild/Restoration!

    Well done mate, good quality build. Thanks for the updates!

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