Yep, a huuuuuuuge roll of it. Enough to do roof, floors and inside of doorsOriginally Posted by andy-v
fatmat.... can get it off ebay
Yep, a huuuuuuuge roll of it. Enough to do roof, floors and inside of doorsfatmat.... can get it off ebay
Got the rest of the headliner glued in place today - the final look is okay, as good as it is going to get without having to unpick the seams of the liner and re-sew it.
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Where there are creases, I've tried to have them in places where I've seen them in original cars - i.e. at the top of the windscreen pillars, and then used the sewn-in seams to fold and hide extra material to pull it tight. It's not a perfect job by any means, and I can't see how you could get it any better???
Also got the passenger side rear quarter in:
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We also spent almost all morning trying to get the front screen in - what a pig of a job! The new screen is very, very tight. It's now in, but the seal at the top corners is just not level - despite plenty of lube and lots of hitting it. It will leak, if left as-is, so we'll have to spend some more time on this.
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Finally, we got some more fatmat cut and installed on the floor. This is just the first lot - I'm going to cover the tunnel as well as go up about a foot and a half up the front firewall; will probably also do under the rear seat, inside the doors and inside the rear wheel arches:
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Found some door switches too, so that saves having to find uber-rare mk1 items... they're mk2 escort/capri units, so not an exact match to the early 'mushroom' escort units. They'll do the job though.
Next weekend we'll get the rear screen fitted and start to look at things like the door and boot seals, do the rest of the soundproofing, lay out the wiring harness, stuff like that.
A couple of tiny pebbles chipped off the mountain of work though!
Got a bit more done today:
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Got the rear screen in - it's a better fit than the front and the seals went in quite nicely. No issues
Also fitted the fresh air intakes and the heater water bulkhead fittings - these were neat little parts supplied by T7Design.co.uk:
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Got most of the interior sound deadening material applied (Fatmat) - did almost all of the front bulkhead, the footwells, insides of the doors, as well as some flat areas up underneath the dashboard. I'll probably use some foam and stick it under the dash with spray glue, as clearly it won't be getting any carpet as extra insulation up under there!
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Also got the time to refit the wiper motor and a few other bits and bobs. The pedal box is just in temporary at the moment, so we could cut the insulation to shape - it will be coming back out as I think the throttle pedal needs bending slightly at the top to get a straighter angle for the cable to pass through the bulkhead. If we fitted a cable now it would probably end up wearing through as it's at about a 30 degree angle from the top of the pedal arm to the bulkhead hole. Ho hum!
Also, my fabby new Stack dashboard gauges arrived, so I can start building up my replacement dash tomorrow
Oh, and I forgot to mention, the new door seals I bought from Jumblemaster on ebay are- the drivers door wont close further than about 3-4 inches
I've bought another set from Retrobolts on here, as they're supposed to be thinner than the usual aftermarket stuff, so you don't need to slam your doors.
Got all of the sound deadening installed now, including the tunnel:
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We got most of the door hardware built up and installed - new door handle seals, new solex locks, new striker plater, new seals and window channels:
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(couple of points to note - the bodyshop didn't make a fantastic job of polishing, so there's nasty lines and bits of overspray I need to go over with some G3.... the other point is that my door handles are
Still have the window regulators to fit and the quarter light glass to install though.
The other thing I've been working on is getting the 6 dial dash pod underway - cutting out the relevant holes. All my remaining Stack gauges arrived, so I'm eager to get it built up
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Dad has been busy on his Anglia, so not much more than the above has happened with the Escort since last week. Hope to get the doors finished this week and then move on to the electrical, pipework and other under-dash hardware (remote servos, column, etc).
May even take a day of holiday next week to get cracking on with it
Last edited by MegatronUK; 06-12-2015 at 20:17.
Coming together nicely now...looking good
Forgot to mention, we put the new window drop glass into the frames using a cut up mountain bike inner tube. The original rubbers were rock hard and perished - worth a try if you need to do the same!
Got all the remaining glass in and door hardware installed today. Locks, handles and window regulators all working
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Some of the new window seals needed trimming to fit properly.... argh! why can't stuff fit as good as the originals?
Also got the new headlamp bowls installed:
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Starting on laying out the wiring and fitting equipment up under the dash this weekend - servos, heater, column, etc.
I like that last pic,
Finished building the dash pod today:
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Stack clubman tacho (will mount the shift light somewhere else), 160mph electronic speedo, 2bar electronic boost gauge and electronic fuel gauge. Also warning lights for full beam, indicators, alternator/battery and a light for the Cossie diagnostic flasher.
The Stack oil pressure/temp and water temp gauges are all mounted in the centre console. Shouldn't need any more warning lights as the buttons all have them built in (side/main beam, hazard, fan, etc).
Quite pleased with the way it's turned out
Looks awesome a nice change from the normal six dash what are you using for a speedo pickup?
I got the Stack wheel speed sensor - I'll need to make a bracket to take a reading from one of the wheel studs or something similar. I would have liked to use the T5 output, but sadly it doesn't appear to be an option.
lovely job there mate how much fatmat did you use I want to do majority of car(mk2) did you sell your xe bits??
I bought the 60 square feet roll. It's enough to do all of the interior floor, front bulkhead, the roof and the doors (as well as the insides of the rear quarters). I've got just enough left to go under the rear seat, but haven't used any in the boot - but I don't think it really needs it. If you do get some, then make sure you've got a way of heating it up; a space heater (we used a big oil burner heater in the workshop) or something is ideal, as it doesn't work very well unless its nice and hot and pliable.
I've still got all the XE bits, but they're all going in my dads 105E - he's busy fabricating a custom bulkhead at the moment and has already got the engine mounts made up. I think it's going to be a bit bonkers
Bit of a disappointing day today - started with plans to get the roll cage in and then start to get interior bits done, but hit a problem with the bar across the front screen...
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There is no way the sunvisors will fit - the bar itself is directly over the top of where the sunvisor brackets screw to the roof. This has got me stumped, anyone else with a Safety Devices bolt-in cage, how have you solved this?
Got the heater and servos back in place though:
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I was hoping to try and fit the electrics/fusebox and ecu behind the new centre console, but with the heater there there not going to be enough room, it looks like we'll have to fit a drop-down panel hinged at the top of the servos and attached via a catch to the bottom edge of the dashboard.
The other thing that has caused a bit of concern is when we tried the new wheels and tyres on, to check the ride height using the decambered springs:
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At first sight, it's not too bad - this is with -2" decambered springs and 1" blocks... it could probably do with 2" blocks to be fair... however, the passenger side is almost 20mm lower - it looks perfect... so there must be a problem with the suspension, so we raise the lift and have a look:
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.. it's quite easy to see that the passenger side spring is virtually flat, but the drivers side is still curved. That explains the difference in ride height.That'll be a call to Gartrac next week to see if they can sort it out.
Oh, and to top it all off we think we've got a reaction in the new paint in a few places on the front wings. Fan bloody tastic....
Last edited by MegatronUK; 20-12-2015 at 19:28.
Looks like you have been sent a normal spring and a decambered spring. I'm aure gartrac will sort it out no hassle though.
Yeah, I agree re: the springs - though I sent them as a pair to Gartrac to get decambered. Looks like one just hasn't been done quite enough.Looks like you have been sent a normal spring and a decambered spring. I'm aure gartrac will sort it out no hassle though.
The whole paint thing has just been a pain in the arse from start to finish
Nearly finished the centre console - just need a leather gaitor and a nice rotary dial for the Corsa EPS mounting somewhere.
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(ignore the silver screws on the sides - I ran out of black ones, they'll be replaced when I get some more!)
Got some pipe ends ordered for the under-dash brake fluid pipes as well as the vacuum connectors to the remote servos. Next thing on the car is probably the column and final fitting of the pedal box.
the car is looking great now, i like the centre console, i have plans to make something similar myself.
did you fit a heater from T9 as well as the inlets, just looking for a modern alternative
Hi, the heater is from Carbuildersolutions (http://www.carbuildersolutions.com/u...car-heater-kit), although some of my bulkhead water fittings are from T7 Design.
My heater bubble was removed years ago when I did the XE conversion, so I lost the original heater then and didn't really feel the need to put it back for originality; hence the modern heater. Should be a lot more efficient, too.
T7, my mistake lol. now having a look through the link you posted. lots of good stuff on there thanks
Got the lower vents installed in the centre console today:
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Also built the pedal pedal box back up and bolted it on to the bulkhead with some nice stainless allen bolts. All the old holes in the bulkhead are sealed up with new rubber grommets - I don't think I'll be able to use any of them. What is everyone else with a YB using for a throttle cable, btw?
Got the bulkhead -4 AN brake fluid connectors in place as well - I'm not having any pipes at all running through the bulkhead now, so everything is connected like this. Much neater imo.
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Mounted the CBS fusebox above the remote servos in the passenger footwell, it hinges up to mount flush with the bottom edge of the dash.
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Final picture of the the under dash progress so far. Next job is to fit the Corsa EPS column back in, and get the wiring in place through the bulkhead; we're doing something similar to the pedal box - mounting a polished alloy plate in the engine bay to hide all the holes. Biggest problem is the size of the hole needed for the Cossie engine loom - it's around 1.5" diameter and some of the connectors (such as the coil pack ends, or the ignition amplifier) are really wide.....
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Well, after getting back on to the bodyshop and talking to him, the painter has been out to look at the car and has decided to repaint it. There are just too many problems in the paint now showing - tiny pin holes in the lacquer on the front wings and hundreds of fish eyes along the drivers side of the car that you can see in the right light; you can't see them in natural daylight, or with the car at normal height, but on the ramp when looking down or from below, they're clear to see.
So, it's everything back off - well, doors, seals and glass anyway this weekend with a view to getting it back to them next week. It's really annoying, but I couldn't face keeping the car the way it is now.
Absolutely gutted for you to here this.
It's the fact it's another step backwards - we were making great progress getting it built back up. But it really couldn't have been left as it was. I've been told it will be redone within two weeks, if we can get it to them asap. So that's going to be up to dad and me to get it done this weekend.
At least it hadn't got to the point of getting the engine and box back in, or interior bits, before we noticed the problems in the paint. That would have been completely demoralising!
Well today was a totally soul destroying task - we took everything back off that we'd put on; windows out, door seals, glass, locks and handles, headlight hardware. The only thing left on now is the column and a few bulkhead connections that shouldn't be getting touched.
One or two things left to sort tomorrow (adjust the drivers door a little, since it didn't fit quite right since being re-assembled), and then hopefully get the car back to the bodyshop to be painted a second time.
I'm guessing it's not going to be until February where we can get back to the position we were at just before christmas. Totally gutted.
Gutted....
Very impressive, I see you love a challenge.
Tell me about it
I was hoping we would be putting the loom in by now and starting to think about getting the engine and box back in.
some nice touches going into the car the centre console the stack gauges etc.. its come on leaps and bounds since I last seen it..Tell me about it
I was hoping we would be putting the loom in by now and starting to think about getting the engine and box back in.
Since we already took everything back off the car yesterday there wasn't much to do today other than go around and take a note of all the areas on the paintwork that need resolving. In all honesty I think it's going to need a full repaint. Hopefully the car will get picked up first thing this week.
The only other thing we could do was mock up where the RST Recaro seats would fit. They do indeed bolt straight on to late mk1 / mk2 seat rails and they do fit without modifications, but as one or two others have found out, this brings them too far forward and too high compared to the original mk1 seats. Personally, compare to where they sit in the original mk1 position at the furthest position back on the rails, I think they need to be moved at least 4-5" back, and the front dropped by 1-2". That means they really need to be mounted like this:
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That's mocked up with the seat at it's furthest back position - I can barely touch the pedals properly there, so I should think one or two clicks on the adjuster would make it perfect for me, but still allow someone a little taller to drive (plus a healthy amount of further adjustment to bring it forward). What's the height look like compared to other setups? With the full Corsa EPS column and Corsa wheel it feels okay (remember I'm using the whole lot - not a Corsa lower on to an Escort top), without being hunched over the wheel nor needing to stretch too far for it. It's such a long time since I sat in and drove the car with original(ish) seats and the wheel that I can't remember what it was like. I've got some adjustment in the corsa column; plenty left/right, some in/out and a smidge up/down (via a few washers).
This means four holes in the floor and a couple of 1/2" to 3/4" spacers under the front feet. Rather than butcher my original seat rails, or weld extensions on to the original chassis box section, this should be easier to do and also easier to reverse in the future. Anyone else with RST Recaros in a mk1, what have you done?
Last edited by MegatronUK; 10-01-2016 at 16:24.
Just finished the last piece of interior trim - I've taken the original 'wood' dashboard trim (haha, there's a joke!) and covered it with the same foam and then alcantara as I did with the door cards and centre console. It'll cover the holes in the dash (hazard light), as well as cover the heater control panel that I removed when we put the new heater/blower in.
So, here it is:
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Once it all comes together I think it should look pretty good.
Well the car is now back in the hands of the bodyshop and they've already started rubbing it down again. Two weeks was the estimate. Fingers crossed......
Fingers crossed for ya mate! Doing a great job there! a.t.b.
Keep calm mate, paint finish is critical, all good projects are build/strip out/build/strip out,,,, it's only way
Chin up
Regarding the seats: Escort and Fiesta Recaros have a slightly different base to the original 3-door Cosworth ones (I think) - if you could get hold of a pair of those, they should sit lower down automatically. By about 1.5", I think.
Might be worth investigating...?
An update to say that the paint is taking longer than expected as the bodyshop has taken the entire car virtually back to bare-metal. As of last Friday it was all back in primer again with a view to getting colour on this week. It's taking longer than expected, though they have kept us in the loop with what they are doing this time, and I'd rather have it all done properly, including all the minor imperfections we found with the previous finish.
Hopefully not much longer and then we can have her back.
Latest news is that, surprise, surprise, the car is still not painted
So far it looks like a few panels have been rubbed down in various places and primer put on. But not a great deal more. I'm at a point now where if it's not done within the next week or so I'll need to consider what options I have to take this forward.
Would never, ever use them again.
This is extremely annoying and can even cause another unfinished project due to people like this. They are complete piss takers in my view. Yes and as you can guess I have had my share of pre Madonna car painters. But my latest project was in the hands of a excellent lad with a great reputation. I had not used him before but heard a lot about him . I contacted him and discussed what I wanted. He did the car in the time required with no excuses and did an excellent job for a fair price. This is all use car enthusiast ask for.
Anyway he's not a stones throw away from you and is well known in cossie land. He's called Gary and is based at Langley Park
Well on a spur of the moment I decided to take this afternoon off work and popped in to the bodyshop on the way home. Would you believe it, but the Escort was in the spray booth, getting cleaned down with panel wipe.
I was promised it was going to be painted later this afternoon, so we shall see. I just hope that they've sorted all of the paint and finish problems that I listed - it was all masked up so I couldn't see, and only the young apprentice lad was around and he'd just been told to clean it down (the primer from the other day had all been rubbed down), so it did look ready to paint. Fingers crossed it comes out better this time.
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