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dasadrew

17-07-2007, 07:49

Work has kicked progress in the teeth over the last couple of weeks, but managed to advance a bit over the weekend and am taking the week off to press on.

Gearbox is in after a struggle. The quick-fit solution I used basically didn't work. I followed some info from years ago when I bought the inserts for the bell-houing and M12 cap-head bolts. I can't remember where I got the info from, but it was a reputable source at that time.

It started off when I drilled out the threads in the gearbox eyes and found the bolts were too big for the casting recesses. Out came the lathe from its hibernation and the boltheads were turned down. After some fettling with a Dremel and grinding wheels, I finally got the bolts to fit in from the casing side.

Fitted gearbox under the car and then couldn't get the bolts to align with the threaded inserts in the bell-housing. To cut a long story short, the whole clearance issue was just not panning out. Finally had to admit defeat and take off bell-housing. Mated Gearbox to bell-housing outside of car and used the old cross-member lowering trick to get it all back and fitted. To be honest, even if the bolts had fitted, it would have needed some special tools to get to the upper gearbox bolts. Hats off to peops who have sorted this like Dave and no doubt Kel - I couldn't master it!

Two or three gearbox refits at 30°C were slightly fatiguing to say the least.

http://www.redslate.co.uk/upload/pics/DSC03223.JPG

http://www.redslate.co.uk/upload/pics/DSC03224.JPG

Also found that the gaskets I'd bought for the gearbox years ago had shrunk, so had to make up new ones - fortunately having some gasket material to hand!

WIth gearbox and propshaft in, I finished off the fuel line fitting. Can you believe it - after having obtained the correct push-on clips over the rear axle, one of the nipples that you push them on to broke off as I was fitting it! Self tapper rescue team arrived.

Didn't like the floppiness of the fuel line over the rear wheel arch, so introduced a new pipe clip to keep the lines tidy. Suppose car will be "modified" now.

http://www.redslate.co.uk/upload/pics/DSC03234.JPG

Overall impression:

http://www.redslate.co.uk/upload/pics/DSC03231.JPG

rsjohn1

17-07-2007, 08:04

Looking real nice mate!! was thinking of doing the same with my gearbox but na ill do it the way it was meant to be.

keep up the good work!!!!!

regards john

Dave1800BDA

17-07-2007, 08:10

i like that very good work drew, i can now see the spacers used on the propshaft, they are the same as the ones fitted to my car.
I agree the fuel lines do seem floppy but i did use two clips to secure line and it doesnt seem too bad

looking great drew

Banishit

17-07-2007, 08:15

Looking awesome there Andrew

vinny

17-07-2007, 11:25

Looking awesome there Andrew

agree, smashing work das :salute:

graham John

17-07-2007, 12:36

light at the end of the tunnel Drew,

looks smashing,

cheeRS

errol

17-07-2007, 12:39

Hi,

Thats look one clean car. Well done!!,

Errol

dasadrew

17-07-2007, 17:38

Managed to get the dash painted today. It's quite a significant milestone, as I can get on with pedal box, steering column, heater etc., which I didn't want to do whilst there was another interior paint-job waiting.

Was surprised when sanding back to discover that the dash is two-tone (satin and matt). After years of armor-all and Auto Glym both sections had taken on the same shimmer. As the paint flaked off, however, it became clear that the part between coaming and windscreen is matt.

http://www.redslate.co.uk/upload/pics/DSC03243.JPG

Banishit

17-07-2007, 18:10

it became clear that the part between coaming and windscreen is matt

wheres the Matt start then drew ? and whats a coaming ?

191964

17-07-2007, 18:16

speaker grill / slots ?

Banishit

17-07-2007, 18:17

looks like on the edge under the dash top

dasadrew

17-07-2007, 18:24

Coaming is what you smarten your hairing with.

Seriously, the coaming is what you call the dash-top. Coaming I know from planes where it is the bit which extends to throw the ****pit instruments into shade making them more easily readable.

Matt / Semi-Matt division is exactly under this dash-top.

Banishit

17-07-2007, 18:36

learn something everyday thank you oh wise one, should have asked the wee brother hes an airline pilot, then I could have looked not so daft LOL

dasadrew

17-07-2007, 21:29

learn something everyday thank you oh wise one, should have asked the wee brother hes an airline pilot, then I could have looked not so daft LOL

My fault entirely, Brian. Nothing wise about using jargon. Just use it so often it had escaped my attention that it was actually jargon.

macjam

17-07-2007, 21:40

First time looking at this thread today and glad I took the hour out to read it.

Awesome looking car and a credit to you for all your time and effort thats gone into it.

Keep up the brilliant work, you never know you may have inspired another resto.:cool: :cool: :cool:

dasadrew

19-07-2007, 18:31

Thanks for the comments guys!

I convinced myself I had to just hang the nosecone on to see the clearance for an Oil Cooler to be fitted.

I tell a lie, however, I just needed to see some more of that light at the end of the tunnel! (white overpaint from previous owner)

http://www.redslate.co.uk/upload/pics/DSC03255-web.JPG

Joe

19-07-2007, 18:35

Great stuff. Keep the updates coming Andrew it helps with the motivation. :D

CheeRS,

Joe.

dasadrew

19-07-2007, 18:50

Unfortunately the front bits are all just "slaved" on to check general fit and what parts I still have to paint which won't be accessible when they're fitted.

Garden Gate project is nearing completion to which means the RS will be pushed up the side passage (less painful than the back one) for a few weeks whilst the Blue Meanie resides in the garage for some fun driving excursions.

http://www.redslate.co.uk/upload/pics/Garden-gate-2.JPG

mike77cos

21-07-2007, 15:58

I like

dasadrew

15-08-2007, 10:31

Well, my intrepid dreadnaughts, Jaffa continues!

Was originally planning just to tidy it up and park it for the summer hols but have now decided to press on a bit more. Wings are on the list now.

In preparing the "A" pillar for painting (the bit you can't reach when wings are on) I thought I might as well take in the sill as well. ....and the Roof gutter........ and the rear wing.

Have also finally sanded off the white overpaint on the roof. It will finally get a BVR, but wanted to check for any secret rust or filler. None found.

On preparing the wings, I was cleaning off the underseal with cellulose thinners and.... hey presto, the original factory paint on the "A" pillar wing end disappeared too! Did Ford give them a dusting with cellulose paint before doors were fitted? The paint stops lifting off on the edge where it meets original factory two pack.

I've also decided to follow a sure-fire route which will enable me to walk away with a trophy from all UK events (maybe next year...) Only Roger RMinOz could thwart this cunning plan.

http://www.redslate.co.uk/upload/pics/DSC03291.JPG

http://www.redslate.co.uk/upload/pics/DSC03292.JPG

http://www.redslate.co.uk/upload/pics/DSC03293.JPG

http://www.redslate.co.uk/upload/pics/DSC03295.JPG

ian parker

15-08-2007, 11:43

top work as usual Drew, keep going;)

graham John

15-08-2007, 13:50

more pics drew ?

coming along nicely,

cheeRS

dasadrew

16-08-2007, 10:42

Manifold arrived back today from Camcoating. Nice, and no shinneeyy!

http://www.redslate.co.uk/upload/pics/Camcoat-Manifold-01.JPG

http://www.redslate.co.uk/upload/pics/Camcoat-Manifold-02.JPG

Banishit

16-08-2007, 11:20

looks good too

oldskooljoe

16-08-2007, 11:45

Manifold arrived back today from Camcoating. Nice, and no shinneeyy!

http://www.redslate.co.uk/upload/pics/Camcoat-Manifold-01.JPG

http://www.redslate.co.uk/upload/pics/Camcoat-Manifold-02.JPG

That looks mint Drew:cool: good work keep it up:)

dasadrew

17-08-2007, 12:29

Finally got all the goo, underseal, muck, paint, primer off the front wings.

Very pleased with the condition. Just one or two very minor rust traps which I won't bother with (base primer, 2-pack filler primer, 2-pack paint, underseal should keep that bit of rot at bay for longer than the car will last!)

Wheel arches were perfect - no rust. Have started putting a bit of filler on to even out the mole-grip dents from bending the flange round. (done by previous owner, I hasten to add, when he fitted the Group 1 6"x13"s).

:( frustrated that the car is in a giant plastic bag ready for the next bit of paint and I can't get to fit my new steering bolts nor the manifold. Must press on, then I might manage to do them by Sunday evening.

http://www.redslate.co.uk/upload/pics/Front-Wings-01.JPG
http://www.redslate.co.uk/upload/pics/Front-Wings-02.JPG
http://www.redslate.co.uk/upload/pics/Front-Wings-03.JPG
http://www.redslate.co.uk/upload/pics/Front-Wings-04.JPG
http://www.redslate.co.uk/upload/pics/Front-Wings-05.JPG
http://www.redslate.co.uk/upload/pics/Front-Wings-06.JPG
http://www.redslate.co.uk/upload/pics/Front-Wings-07.JPG
http://www.redslate.co.uk/upload/pics/Front-Wings-08.JPG

oldskooljoe

17-08-2007, 13:17

Them wings are looking good:cool:

keep it up:)

Banishit

17-08-2007, 13:35

not a lot wrong with those Andrew, makes a change you missed some yellow LOL

dasadrew

17-08-2007, 15:21

not a lot wrong with those Andrew, makes a change you missed some yellow LOL

Sorry to disappoint, Brian. If it's the photo I'm thinking of, it's bare metal reflecting the yellowish flash tinge! :D

Couple of orange microdots about, but that was the original colour, so no future restorer in 2037 will suspect the car ever was anything but the original colour! ;)

Dave1800BDA

17-08-2007, 15:29

wow they look really good, some work gone on there

delorean mk2 :eek:

dasadrew

17-08-2007, 15:44

delorean mk2 :eek:

PMSL!

Joe

30-12-2007, 17:19

Hi Andrew how is the RS progressing?

CheeRS,

Joe.

dasadrew

09-02-2008, 18:28

Cover came off the car today. Started off the spring by sanding the downpipe back to bare metal, then a coat of VHT Gunmetal. Not sure how long it's possible to leave before heating to cure it, so I got the gas torch out and took it up to a high temperature a couple of times by putting the burner into the open ends.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/Downpipe-01Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/Downpipe-02Medium.jpg

dasadrew

10-02-2008, 13:05

Oh well, every little bit.....

turned out to be quite a pain as one of the threads in the manifold had slightly stripped out, so the stud kept turning. Put in a long bolt which managed to engage in some intact thread left in the casting.

Amazing that the manifold holes don't line up with the studs in the head. Needed a lot of rubber hammer persuasion to slide over the studs.

Engine needs a bit of a dusting off, and don't look at the rusty spacers on the manifold studs - hadn't got new ones (are they available?) and I must admit I'm running out of steam with this shinneeyy stuff. Just want to get it fired up!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03749Medium.jpg

bigjohnie

10-02-2008, 13:39

andrew you have done a lovely job on those brake lines,fancy an all expences paid working trip to glasgow mate:D

wozzy

10-02-2008, 14:44

Thats looking very nice,
i also agree that those brake lines look very well

dasadrew

10-02-2008, 14:52

andrew you have done a lovely job on those brake lines,fancy an all expences paid working trip to glasgow mate:D

I'll think about it.

I've thought. I'll pass that one up this time :D

dasadrew

17-02-2008, 15:36

Time to freshen up the trusty old NOS Group 1 Exhaust System, so the wire toothbrush has been put back into service. Wish I'd stored the exhaust properly, but thankfully, the rust only seems to be on the surface.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03751Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03757Medium.jpg

RS2000&MEXICO

17-02-2008, 16:32

thats a nice bit of kit...:) ...looking good

dasadrew

24-02-2008, 11:25

little by little.....

another tick in the box today - exhaust system on!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03761Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03759Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03760Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03764Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03766Medium.jpg

Dave1800BDA

24-02-2008, 11:33

very good andrew, love the parts labels, how long will they last on there

is it a ford system drew, as mine is a Ti system with earlier part numbers on

Martin

24-02-2008, 13:19

Just noticed this thread. The car is looking amazing Andrew and a credit to all your efforts so far. Keep going and can't wait to see it once finished :notworthy:

dasadrew

24-02-2008, 17:31

very good andrew, love the parts labels, how long will they last on there

I hope long enough to get the first registration process with the German TÜV done :D .

Actually, the Group 1 Exhaust is not street legal in Germany, being an absorption type rather than baffles. I'm hoping the stickers will lend it an air of authenticity - especially if backed up by a microfiche print out which shows those numbers are the correct ones :cool:

is it a ford system drew, as mine is a Ti system with earlier part numbers on

I got mine over the counter from Ford Trimoco Dunstable in the '80's. Funnily enough, it has no F-o-r-d embossed trade mark on it, which seems to indicate it was done by a subcontractor without access to Ford original punches and dies and then stickered by Ford afterwards? Is that what you are referring to?

By the way - steering knuckle bolts and nuts are also now installed - cheeRS!

dasadrew

24-02-2008, 17:32

Just noticed this thread. The car is looking amazing Andrew and a credit to all your efforts so far. Keep going and can't wait to see it once finished :notworthy:

Thanks! I can't wait either, but keep on getting sidetracked!

rwdrs

24-02-2008, 17:46

I've got the same H78 back box and a H75 5230 AA centre section is the H75 centre section different?

dasadrew

24-02-2008, 19:57

The standard exhaust is:

front box: H75AB 5230 AA
rear box: H75AB 5K244 AA

so it seems you have a standard front box and a Group 1 rear box. I was sure they have different diameters, so I don't know how your front joins to the rear? :confused: :confused:

dasadrew

16-03-2008, 12:47

Pedal Box and Radiator got a bit of a buff up. Nothing spectacular really.

I got a local radiator shop to do a pressure test as it's not been used for about 15 years! Everything was ok. I had it recored a long time ago to be more akin to the HD radiator which used to be available with more matrix rows.

http://i221.photobucket.com/albums/dd284/dasadrew/Pedal-Box-12Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/Pedal-Box-13Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/Radiator-01Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/Radiator-02Medium.jpg

dasadrew

16-03-2008, 12:48

upload glitsch - duplicate post deleted.

RS2000&MEXICO

16-03-2008, 16:00

very nice drew...i have got to do my pedal box;)

grum

16-03-2008, 17:08

:cool:

69-johny-rs-07

16-03-2008, 17:36

;) very good read:read: , stunning car ;) wish i had the patients...

dasadrew

23-03-2008, 18:14

The long haul continues - Oasis method (little-by-little)

Radiator in, accelerator cable in, dipstick and extension in, NOS top and bottom hoses, NOS oil pressure line. Sandwich plate for oil cooler can just be seen.

New clutch cable was a barsteward - at first I thought it was too short. Took a lot of pulling and levering.

Have started to clean up the wiring loom.

Must knock up some brackets for the oil cooler now.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03790Medium.jpg

vinny

23-03-2008, 18:36

been waiting for an update das, looks great :thumbright:

oldskooljoe

23-03-2008, 18:52

looking good:cool:

dasadrew

23-03-2008, 20:16

Nowt on the box tonight, so decided to finish off those oil cooler brackets after all. It's amazing what useful and adaptable bits of metal the kitchen department of IKEA has in store these days ;)

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03793Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03792Medium.jpg

lee bishop

24-03-2008, 09:37

tidy install sir, coming along nicely

ian parker

24-03-2008, 10:21

love the detail Andrew, why did you secure the extended dipstick to the bulkhead ??

dasadrew

24-03-2008, 11:00

love the detail Andrew, why did you secure the extended dipstick to the bulkhead ??

a) Thanks!

b) 'cos it said so on the box!

(seriously, the fitting instructions for the Group 1 Engine Kit from Ford are very explicit about this point and even have a photo showing it fitted on the firewall.)

RS2000&MEXICO

24-03-2008, 11:56

thats looking very nice andrew :cool:

dasadrew

29-03-2008, 16:53

VERY pleased to have finally got hold of this bit. Have had a search on eBay going for a year. Bought one a few months back but it never arrived :mad:
This one has the EXACT same part number (not just generically similar). Just need to swap over the Ford and Bosch housing covers and the job's a good 'un ;)

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03821Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03824Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03825Medium.jpg

oldskooljoe

29-03-2008, 17:08

nice one drew:cool:

dasadrew

30-03-2008, 17:03

Oil Cooler now fitted. Will route hoses and fix P-clips after fitting all the rest of the bits like loom etc., to ensure best positioning.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03833Medium.jpg

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03834Medium.jpg

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03836Medium.jpg

Refurbed the Ford regulator cap and did the transplant too.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03837Medium.jpg

Martin

30-03-2008, 17:21

looks stunning Drew :cool:

paul spence

30-03-2008, 18:02

nice work drew:D

bigjohnie

30-03-2008, 18:51

dasadrew

30-03-2008, 18:54

andrew my mk1 had one of them fitted are they hard to find my alternator has a loom that plugs into that box

Exactly. They keep you regular :D

Dave1800BDA

30-03-2008, 19:02

looks great andrew:cool:

vinny

30-03-2008, 19:29

my mk1 still has one fitted though i think its got yellopw tape round the bottom

dasadrew

30-03-2008, 21:06

my mk1 still has one fitted though i think its got yellopw tape round the bottom

Yep! My original one had yellow tape. The Bosch replacement has green. I didn't have any yellow tape to hand today, so sealed it in the meantime with "Bosch Green"! Retrofit to follow!

dasadrew

06-04-2008, 08:19

Rather glad I decided to re-insulate the loom. Discovered this little mischief hiding under the wrapping. What you can't see in the photo is the adjacent cable which was also chafed so that the wires were exposed.

http://i221.photobucket.com/albums/dd284/dasadrew/DSC03842Medium.jpg

All better now! Spliced joint and heatshrink sleeve for one cable. The other one wasn't too bad, so it got taped up with self-amalgamating tape. (You can see the second exposed cable in the background.)

http://i221.photobucket.com/albums/dd284/dasadrew/DSC03843Medium.jpg

http://i221.photobucket.com/albums/dd284/dasadrew/DSC03844Medium.jpg

dasadrew

08-05-2008, 18:55

Spruced up the alternator today. New bearings, brushes, tidied up a bit.

http://i221.photobucket.com/albums/dd284/dasadrew/Alternator-02Medium.jpg

http://i221.photobucket.com/albums/dd284/dasadrew/Alternator-04Medium.jpg

http://i221.photobucket.com/albums/dd284/dasadrew/Alternator-06Medium.jpg

RS2000&MEXICO

08-05-2008, 19:24

i must say that you do restore a car to the max....well done :D

Hoogi

08-05-2008, 19:59

Not sure if I've seen anyone go to this much depth of detail.

I can only take my hat off to you..........if I was wearing one !!!!!!!

Please keep the pics coming as this really is a great Resto story.

Drew, can I also ask what size Goodridge fittings are used on the Mocal Oil Cooler ?

Many thanks..............

Joe

08-05-2008, 20:38

Great attention to detail as always Andrew :thumbright: .

CheeRS,

Joe.

Banishit

09-05-2008, 07:53

youve got way too much time on your hands Drew LOL

nice job on the alternator mate

dasadrew

09-05-2008, 08:00

youve got way too much time on your hands Drew LOL

That all changes soon! My posting to France ended last week, so I'm in process of wrapping up odds and sods and starting to pack. Have rented a house in Germany for the time being - with double garage and little workshop and, purely by coincidence, about 300 yards from my RS2000 spares lock-up. I've got a local body shop and sprayer there who I've used before. Hoping to make a big leap forward in Summer as long as the move goes smoothly.

vinny

09-05-2008, 10:10

That all changes soon! My posting to France ended last week, so I'm in process of wrapping up odds and sods and starting to pack. Have rented a house in Germany for the time being - with double garage and little workshop and, purely by coincidence, about 300 yards from my RS2000 spares lock-up. I've got a local body shop and sprayer there who I've used before. Hoping to make a big leap forward in Summer as long as the move goes smoothly.

good news das, goodl uck with the move and getting the old girl finished

rwdrs

09-05-2008, 10:42

youve got way too much time on your hands Drew LOL

nice job on the alternator mate

certainly cost a lot more than variation I used, the previous owner of my car fitted a new fan belt and managed to break the casting at the adjuster bracket:rolleyes:
I bought a brand new 70A double pulley Ford unit off the Bay for 20 Euros (incl. P&P).:D

Gonna be nice when she's finished that Tango Escort:cool:

graham John

09-05-2008, 16:34

coming along well there andrew,

keep the updates coming,

cheeRS

dasadrew

24-06-2008, 19:22

Said goodbye to the RS today...
.
.
.
.
.
.
.
.
.
.
well, at least until I see her again on the other side of the Maginot Line in a couple of weeks!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/DSC03993Medium.jpg

grum

24-06-2008, 22:12

will be super when done andrew - details some of the best we've seen on a resto

:cool:

Banishit

25-06-2008, 07:59

least its not raining there Drew, paints a bit patchy dont you think

grum

25-06-2008, 09:56

least its not raining there Drew, paints a bit patchy dont you think

at least the stripes are of an original design :)

dasadrew

25-06-2008, 17:34

least its not raining there Drew, paints a bit patchy dont you think

Cheeky bu$$er! BTW, what's rain?

mexicostids

25-06-2008, 21:11

wow !! how did i miss this thread great job no nut or bolt untouched :cool: good luck nearly there now.

dasadrew

30-12-2008, 12:09

Well, it´s taken a bit longer than expected to get the move from France to Germany done. Summer was good, so spent the weekends on the pushbike rather than under the car.

Decided to sort the garage out before knuckling down again. It´s a rented house so I didn´t want to install any permanent shelving etc. Quite pleased with the result and it can all be taken with me when I find somewhere permanent. Still need to clean a few corners up.

Scissors Lift is an admission of old age creeping on - couldn´t be naffed to faff around on my back on the concrete floor anymore. It was a good deal off the ´Bay - new and unused at half price and not one of those Chinese jobs either!

Have been picking up a few more parts - Seat cover set arrived from Aldridge yesterday :). Also got a "proper" Bosch red coil and a few other odds and sods. Have got a slot at the paintshop lined up - just need to get some panels lined up first and it should be in the shop in a couple of weeks - YIPPEE!!! :D:D

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/Garage1Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/Garage2Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/Garage3Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/Garage4Medium.jpg

Dave1800BDA

30-12-2008, 12:44

garage looks great andrew. love the scissor lift:cool:

hope you can get on with the car now

happy birthday again:D

Banishit

30-12-2008, 12:59

nice bit of space after the other rabbit hutch there Drew

wheres the blue machine, got rid credit crunch :)

dasadrew

30-12-2008, 13:28

Still got it. No credit = no crunch! ;)

vinny

30-12-2008, 13:57

garage lookin good das, look forward to seeing car painted

paul spence

30-12-2008, 17:39

looks well that drew:cool:

lee bishop

30-12-2008, 18:05

spent the weekends on the pushbike rather than under the car.

http://i47.photobucket.com/albums/f162/70hornet/401px-Velocipedist.jpg

:D

oldskooljoe

30-12-2008, 18:06

looks well does that set-up lark:cool:

cant wait to see the scort in pent nah:yeah:

oldskooljoe

30-12-2008, 18:07

http://i47.photobucket.com/albums/f162/70hornet/401px-Velocipedist.jpg

:D

bet you remember them well Lee:D

dasadrew

30-12-2008, 19:41

http://i47.photobucket.com/albums/f162/70hornet/401px-Velocipedist.jpg

:D

Contrary to popular belief, most Penny Farthings left the factory with both wheels the same size. The Ashley Wheel Company Ltd. offered a tuning front wheel which claimed to improve torque and give a better sound. Many owners of the Penny Farthings bought this kit, only to find out that the front wheel didn´t fit right at all. However, most persevered with crowbar, hammer and pliers and got it to fit somehow. Thus the proliferation of Penny Farthings with disproportionately large front wheels.

The Ashley company went under in the Great War of 1914-1918 but was revived in the late ´70´s. They no longer produce wheels, but motor vehicle exhaust systems.

dasadrew

01-01-2009, 15:30

Things are moving again. I´d never been happy with the fit of the new RH sill at the front. As usual, it was designed to fit over the original sill, so had to be persuaded a bit as I used it to replace the original.

Anyway, out came the 5lb hammer and a bit of reshaping occurred. Have just leaded the area to build up a decent contour again.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/RHSill01Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/RHSill06Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/RHSill07Medium.jpg

garthbtp

01-01-2009, 15:41

Nice work Andrew car getting there now.

Cheers Garth

Banishit

01-01-2009, 17:40

as usual top work Drew

emily

01-01-2009, 18:25

cracking tale , keep up the good work . can't wait to see the end product :cool:

dasadrew

09-01-2009, 18:07

Well, after about 15 years, I´ve finally done the last bit of welding! Treated the seams to a spot of lead although they won´t be seen when the nose is on.

I found it was near on impossible to get good alignment of the front wings simultaneously where they adjoin bonnet, windscreen scuttle, door front edge, front panel and lower sill. Had to plump for the bodgy bit being where the wing lower quarter joins up to the sill. I thought it was all ok but welding the front panel seam obviously force the wing to creep a bit. Oh well - the next resto will be better.

All stopped at the moment as it´s down to minus 4°C in the garage after a frosty spell last night (minus 18°C).

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_0823Large.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_0825Large.jpg

lee bishop

09-01-2009, 18:31

very nice work there das, dont fret about little flaws in the build, im sure ford never paid the same attention to detail

well done ;)

windy

09-01-2009, 18:59

Blimey - bit of lead loading - not seen that done for a while.

dasadrew

20-01-2009, 16:34

Wing welds nicely primed and sealed with bodywork sealer, then painted. No more rust there!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_0838Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_0839Medium.jpg

I reckon this door can be salvaged without too much welding :D:D

A previous owner had sprayed it full with wax and there is virtually no rust anywhere. You have to get lucky once in a while!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_0841Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_0842Medium.jpg

RUDDY

20-01-2009, 16:50

Looking really good, a credit to your time and effort .

cheers, Paul

lee bishop

20-01-2009, 16:52

nice work as ever dasa, that door looks in good shape too bud :D

andym

20-01-2009, 16:55

Just keeps getting better.... Its just a credit to you..:yeah:

dasadrew

27-01-2009, 19:43

Well, after a lot of soul searching, realising I just don´t have the time to spend on the car, and realising I´ve spent nearly 15 years alone in the garage with the bloody thing, I took the decision yesterday to part company with my old friend Jaffa the orange Escort

for a few weeks while it´s in the paint shop!! Yippee, can´t wait. Most removable bits like doors, bonnet, boot, nose are there now. Rolling shell gets picked up sometime this week.

Banishit

27-01-2009, 20:45

all that work and your not painting it yourself ;)

dasadrew

27-01-2009, 21:34

all that work and your not painting it yourself ;)

You know me Brian - all mouth :D

It was getting to be a race to be able to get the 2-pack paint. Stopped selling it here. Only available on special order. All water based now. Colours run if it rains :rolleyes:

grum

27-01-2009, 21:55

the hoist looks a handy bit of kit :cool: bet your knees are thanking you :)

dasadrew

27-01-2009, 21:57

the hoist looks a handy bit of kit :cool: bet your knees are thanking you :)

It´s not the lying under the car that knackers you, it´s the getting up and back under again when you need another spanner or whatever! It really is a dream - saved up over a couple of years before I could justify the cost!

graham John

28-01-2009, 08:17

It´s not the lying under the car that knackers you, it´s the getting up and back under again when you need another spanner or whatever! It really is a dream - saved up over a couple of years before I could justify the cost!

i know the feeling Andrew, these days if i fall over i dont get up straight away, in fact i have a look around to see if anything neds doing whie i am down there:o

cheeRS

bigjohnie

28-01-2009, 13:37

you had me there for a minute ,thought it was going.this is a like reading a good book you cant wait for the next chapter

dasadrew

04-02-2009, 17:06

The deed is done. The die is cast. The bird has flown the nest.

Jaffa got trailored to the paintshop today. Bit of a delay as we had freezing rain and black ice last Wednesday so the bodyshop was suddenly booked out for a week!

It's a really funny feeling that, when it comes back, I've "just" got to assemble the bits. No more rust removal. No more welding. No more filing and sanding.

It was in 1990 that I took the car off the road for a "tidy up". 19 YEARS FFS !!

I'd gone so much into a "must look for that bit next year" mode that I'm suddenly realising that I now need a few last minute bits in a hurry!

Had a stroke of luck with finding a wing top relay. Sorting out the garage I found that it is the EXACT same relay which is on one of my steering columns :). The one on the steering column is as bright and shiny as the day it was fitted! No photos at the moment as the camera is playing up.

dasadrew

05-02-2009, 16:42

Very pleased today when I called past the paint shop. Work is well in progress. Doors and bootlid have been primed and "fillered" (not sure what the correct english term is - it's the spray coat of high solids to allow the final surface imperfections to be evened out). Bonnet is proving to be a surprise. They said there are lots of undulations and peaks and troughs in it, so it's having a thorough polyester filler build up to level it all out.

They then want to leave all alone for a good week to let the primers and filler coats fully harden out before final sanding off and painting.

I'm still in a state of:

a) excitement
b) panic!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/PAINTSHOP01Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/PAINTSHOP02Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/PAINTSHOP03Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/PAINTSHOP04Medium.jpg

Frosticles

05-02-2009, 17:42

Looking suberb Andrew, Not long now. :)

lee bishop

05-02-2009, 19:34

looks bloody great dasa, but did you have to lend them your car lift??

:D

Aled

05-02-2009, 21:24

Looks like it's coming along well Das.....bet you have a nice warm feeling inside now :D

dasadrew

07-02-2009, 12:59

Panic is really setting in now.....

Popped in this-morning and the final "contour check" mottle has been applied :eek: :eek:

The last car they did for me took 7 months, so I've now got another project on the go in the garage thinking it will be end of Feb when I get the RS back :eek:

Hoarder-Strips (black back panel borders) arrived today in the post, so one panic less! Cheers Rob!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/PAINTSHOP06Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/PAINTSHOP08Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/PAINTSHOP09Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/PAINTSHOP10Medium.jpg

Banishit

07-02-2009, 13:36

oooo getting closer , nice one

another project in the garage ??

dasadrew

07-02-2009, 13:57

oooo getting closer , nice one

another project in the garage ??

just sorting out a few things on the blue car before spring....

SHIFTY

07-02-2009, 17:39

Not long now!, its a great feeling getting a car sprayed :cool:
Bet your like me though and cant wait to get all the new bits bolted on to her :)
Keep up the good work! :cool:

paul andrews

07-02-2009, 17:49

not laong now m8,gonna be a cracker

RS2000EXPRESS

13-02-2009, 21:15

Blimey - bit of lead loading - not seen that done for a while.
Andrew, this is an excellent way of sealing those seams, what a great job you're doing here. Have not seen this on a Ford since the days of the Ford Corsair when Ford used lead fill on the joint where the top of the wing meets the front panel.

Nice early model this. The Signal Orange RS2000 Mk2 was probably the first I saw and there were loads of orange ones around here when they were first introduced.....and then they all disappeared. Keep up the excellent work, looking forward to seeing it completed.

dasadrew

13-02-2009, 22:17

It's now primed, filled, sanded and has been put aside in the paintshop for 5 days to let all the priming coats gas off.

Orange paint should be going on next week :)

dasadrew

19-02-2009, 16:30

The future is bright. The future is.....

ORANGE !

Jaffa's story can be seen in total on www.rsmk2.com (http://www.rsmk2.com)

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP15.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP16.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP17.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP18.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP19.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP20.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP21.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP22.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP23.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP24.jpg

lee bishop

19-02-2009, 16:47

superb dasa, ready for the lakes then??

grum

19-02-2009, 16:57

them holes in the right place ? if so, who says so :)

very nice drop of paint

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP22.jpg

Dave1800BDA

19-02-2009, 16:58

very orange dasa, nice site too:cool:

dasadrew

19-02-2009, 17:01

them holes in the right place ? if so, who says so :)

... the Lady of the Lake, her arm clad in the purest shimmering samite, held aloft the fitting instructions from the bosom of the water; signifying by divine providence, that I, dasadrew, would be the one to get the holes in the correct position ....

dasadrew

19-02-2009, 17:03

superb dasa, ready for the lakes then??

just need to get the Ashley exhaust fitted and the carbs set up ..... :p

grum

19-02-2009, 17:05

Banishit

19-02-2009, 17:05

top job will look the bollox when complete , next week then ?

Chesney

19-02-2009, 17:20

dasadrew

19-02-2009, 18:02

have you been drinking ? :)

2:11

dOOTKA0aGI0

lee bishop

19-02-2009, 19:55

just need to get the Ashley exhaust fitted and the carbs set up ..... :p

shame, maybe next year the eh??

:D

RS2000EXPRESS

19-02-2009, 20:09

That's an excellent orange you have there Andrew!.........looks like a lovely fresh orange!:D;)

Tim.

dasadrew

07-03-2009, 12:49

Painting's done! Might need to slightly correct some of the black borders when I finally hold up the trim bits, rear lights etc., to the car but that will be easy enough at home.

Just need for it to stop snowing now so it can be trailored home.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP30.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP32.jpg

RS2000EXPRESS

07-03-2009, 12:58

Looking great Andrew. Those black bits can't be too bad, a certain amount of error will go behind the thin decal. You can enjoy fitting all they nice bits back on now!;)

graham John

07-03-2009, 16:46

... the Lady of the Lake, her arm clad in the purest shimmering samite, held aloft the fitting instructions from the bosom of the water; signifying by divine providence, that I, dasadrew, would be the one to get the holes in the correct position ....

good, at least Two of us now have them in the right place Andrew:)

car looks lovely

;)
"You know when you've been Tango'd", http://www.britvic.com/Cms/Images/Brands/MainImages/41.jpg

cheeRS

Banishit

07-03-2009, 16:58

looking very nice, not so sure about the clingfilm wheels though, bit heath robinson for me

dasadrew

07-03-2009, 17:00

looking very nice, not so syre about the clingfilm wheels though, bit heath robinson for me

improved aerodynamics m8 !:thefinger:

grum

07-03-2009, 17:09

is that a spare nose cone under yours in the background ;)

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP30.jpg

dasadrew

07-03-2009, 17:15

is that a spare nose cone under yours in the background ;)

FFS you've got good eyesight!!! I gave them one to use as a guide for masking off as mine had been overpainted and the original demarcations had been lost.

grum

07-03-2009, 17:23

FFS you've got good eyesight!!! I gave them one to use as a guide for masking off as mine had been overpainted and the original demarcations had been lost.

heeeeeeeeeeeee :cyclopsani:

theres a few of us on here that check out the backgrounds - never know whats lurking (Graham John is the worst)

dasadrew

09-03-2009, 18:36

Unexpected let up in the sleet, rain and snow this afternoon, so decided to go for it. Note to self: must really clean up the garage!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP33.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP35.jpg

graham John

09-03-2009, 18:42

heeeeeeeeeeeee :cyclopsani:

theres a few of us on here that check out the backgrounds - never know whats lurking (Graham John is the worst)

as if.................:eek:

Andrew, why is there a tree growing up out of your car :D

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/WEBPAINTSHOP33.jpg

cheeRS

rwdrs

09-03-2009, 19:02

signal tangoed:D

dasadrew

09-03-2009, 19:05

as if.................:eek:

Andrew, why is there a tree growing up out of your car :D

cheeRS

Funny you should ask .... when I started the resto 19 years ago I was munching some cherries whilst taking out the headlining. A stone must have dropped onto the floor :D

graham John

09-03-2009, 19:08

that doesnt look like a cherry tree, more silver birch i think:scratch:

cheeRS

dasadrew

09-03-2009, 19:12

that doesnt look like a cherry tree, more silver birch i think:scratch:

cheeRS

Might be. They have branches everywhere. :rolleyes:

grum

09-03-2009, 19:39

nice bit of block kerbing :cool:

graham John

09-03-2009, 20:47

Might be. They have branches everywhere. :rolleyes:

i just knew you WOOD come out with something like that,

cheeRS

dasadrew

09-03-2009, 22:15

Suppose I should turn over a new leaf really. :rolleyes:

Chesney

09-03-2009, 22:27

TREEmendous effort there :D

dasadrew

09-03-2009, 22:28

Thanks. Many people have thought I must be barking mad

Martin

10-03-2009, 08:26

Might be. They have branches everywhere. :rolleyes:

http://blog.al.com/frugalmom/2008/03/medium_aldiLogo.gif

bigjohnie

22-03-2009, 22:52

andrew any more done on the car yet mate.

dasadrew

23-03-2009, 07:03

Yep. Been doing all sorts on it, but nothing very photogenic, so didn't post.

69 Litre tank fitted, plumbed in. Removed and refitted again after dropping a filler neck fixing screw into it and also to enlarge the fuel union hole in tank well slightly.

Rear matt black surround sanded back slightly and modified on the side panels. (Paintshop hadn't quite got it right). Nearly every Escort photo I looked at seems to have a different demarcation line, so I sprayed the side bit to be aesthetically balanced even if not concours correct.

Rear lights fitted. Removed and refitted again after one sidelight didn't work. Finally traced the fault to a chafed wire in the loom. Patched in a new wire section and retaped the whole rear loom to also include some spare wires for any future needs. Rear accessory Ford foglight wire taped in at same time.

Couldn't find any new Ford small horns so bought some new Hella ones (as used in Porsche) which turned out to be quite large. Took about a day to figure out where to position them so the radiator and oil cooler still see some airflow! Tested horn function. Visiting Ear, Nose and Throat specialist today.

New bonnet release cable fitted.

Boot sound deadening fitted and carpet modded for 69 litre tank.

Oil cooler refitted. Lost tightening instruction for Goodridge lines, so trawling Internet now for that.

I'm satisfied with the progress as I'm taking my time to get things right. Searching for correct nuts, bolts washers etc:, to replace rusty items takes a while!

Thanks for the interest! :thumbright:

dasadrew

23-03-2009, 18:40

Oil Cooler and sandwich plate with thermoswitch plumbed in.

Disassembled wiper linkage and regreased spigots and ball joints. Wiper linkage and motor fitted. Slaved it in to the battery to test run and it kept on making a "clack" noise every revolution. After about an hour later I tracked it to a broken captive spring washer under the head of one of the motor mounting screws. Part of it was still hanging on, so it felt tightened up, but half was missing, allowing the mounting plate to wobble ever so slightly. Man, do these things hold you up! Still, I can swap wiper motors in 3 minutes blindfold now.

Carbs and fuel pumps plumbed in - I get the skin grafts tomorrow.

dasadrew

24-03-2009, 16:55

Overhauled the heater unit today. Renewed the manky foam on the catflaps - bit of a patchwork job as I was running out of self-adhesive rubber foam.

Fitted a new heater matrix (eBay). Went to fit a new motor which they sell on eBay as suitable for Escort Mk2, Capri etc. No way. It's a different motor, so will be going back on the Bay. Bought it many years ago, so no recompense.

Chose the best parts from three units which I had, so have got intact ty-wraps too (until they snap at first use!)

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/HEATER03Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/HEATER01Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/HEATER02Medium.jpg
http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/HEATER05Medium.jpg

graham John

24-03-2009, 17:10

were you a Blue Peter or Magpie viewer, Andrew..........:D

cheeRS

dasadrew

24-03-2009, 17:25

were you a Blue Peter or Magpie viewer, Andrew..........:D

cheeRS

Oh yeah! Valerie Singleton, Peter Purvis. Sad when Goldie went though - never liked Shep.

RS2000EXPRESS

24-03-2009, 20:08

Hi Andrew,

I stripped my heater down about 15 years ago and replaced all the sponge, and according to your pictures it looks like you're putting a second hand motor in your heater casing! Only last week I stripped mine down again as an annoying squeak was coming from the motor at fast speed, and I was worried about the bearing wearing out. True enough the bearing was bone dry, so I put a spot of engine oil on it. The engine oil is a bit thick at the moment, but the squeak has surely gone. If only I had done this the first time around it would have saved me a lot of work, please don't forget yours.;)

I also noticed on mine that the slow speed resistor which is attached to a small board, is a bit rusty on the metal bits. So avoiding the resistor itself, I put a tiny bit of waxoyl on the rust to stop it getting any worse and failing,..............this might be something to look out for!

ps. Loved the good use of the dishwasher for cleaning it!:)

Keep up the great work,

Tim.

dasadrew

24-03-2009, 20:32

Good call that! I had blasted out my motor with brake cleaner to get out all the gunge and was going to drop some oil into it. Your post has just reminded me that I forgot to do that!

In actual fact, I've just removed the heater again as I decided to put full soundproofing on the bulkhead. I'll be able to drop some oil in without disassembling the heater unit as I have a few syringes lying about for that sort of task.

dasadrew

25-03-2009, 20:21

Well, due to a tip from Neil (191964) :thumbright: heater unit came out again and got a brand new motor fitted:)

All back in now and all cables, controls and ducts fitted.

Think I've stumbled on a clutch problem though :(. Just by chance noted that the clutch pedal was amazingly stiff. Applied a bit more pressure and the pedal bent !!!:eek:

Seems like the old release-bearing-collar-binding-on-the-gearbox-shaft problem. Everything was OK when I fitted the gearbox. I checked, as I know this problem by heart. Hope I can sort it by unhooking the cable and wiggling the clutch lever in the bellhousing back into place.

Don't know what could have caused it - maybe as it wasn't yet adjusted, but the car was transported up and down ramps etc., the bearing collar may have drifted to a point when it just got askew on the shaft? Any ideas?

All-in-all, the car is going together quite quickly now - should be startable at Easter :yeah:

RS2000EXPRESS

25-03-2009, 23:38

dasadrew

26-03-2009, 05:47

Wow, the pedal is quite strong Andrew...

me too! In actual fact, I was depressing it whilst stood next to the car wiht the foot inside, so I was applying some side force too. The pedal just crumpled! Couldn't straighten it, but had a couple of spare pedal boxes, so robbed one.

....
I don't know what's caused this, never had it happen before. Can you disconnect the cable and move the lever back and forth to see if it feels right?...

Another possibility has just occurred to me. I fitted the gearbox about a year ago. I've had the problem before that the clutch plate sticks to the flywheel after standing a long time, like over winter. Usually I solved this by starting the engine with gear in and handbrake on. Can't do that in this case. Might see if I can just get a rod into the bellhousing and give the clutch plate a knock with a hammer unless anyone has got any good ideas?

RS2000EXPRESS

26-03-2009, 22:23

me too! In actual fact, I was depressing it whilst stood next to the car wiht the foot inside, so I was applying some side force too. The pedal just crumpled! Couldn't straighten it, but had a couple of spare pedal boxes, so robbed one.

Another possibility has just occurred to me. I fitted the gearbox about a year ago. I've had the problem before that the clutch plate sticks to the flywheel after standing a long time, like over winter. Usually I solved this by starting the engine with gear in and handbrake on. Can't do that in this case. Might see if I can just get a rod into the bellhousing and give the clutch plate a knock with a hammer unless anyone has got any good ideas?
If ever I have a clutch plate that has stuck I just stick the car in gear, press the clutch pedal down and rock the car backwards and forwards until it releases......always worked for me, but there are more drastic methods which have been mentioned on here.:eek: The only problem is that with a siezed clutch you should still be able to press the pedal down. You have bent the pedal by attempting to do this, so it does sound like something else is jammed up in there.:scratch:

dasadrew

28-03-2009, 11:38

Found out what the clutch problem is. I think.

Obviously "thinking" wasn't something I was doing when I put the gearbox in.:dunce::dunce::dunce:

RS2000EXPRESS

29-03-2009, 11:33

Found out what the clutch problem is. I think.

Obviously "thinking" wasn't something I was doing when I put the gearbox in.:dunce::dunce::dunce:
I'm sure we have all done that some time or other, glad you are getting somewhere with it now!:)

dasadrew

29-03-2009, 11:59

RS2000EXPRESS

29-03-2009, 22:08

I remember as I was putting the gearbox in, the lever fell off a couple of times. I guess that, lying under the car and working overhesd led me to think in mirror reversed mode when I popped it back into place. Anyway, gearbox out yesterday, lever turned through 180° and all back together. Taking gearboxes out of RS2000's is my favourite weekend acvtivity ....NOT!

Just been trying to get that bloody gearlever nylon screw thread into the gearbox - almost impossible to not get it cross threaded. Can't remember ever having big problems before. It's in now but, to be honest, I've no idea whether the gearbox cut its own new threads on the nylon bit or not!!
These gear levers are bloody awkward Andrew. They are a horrible shape and you're working through the hole in the tunnel. They are supposed to have an ordinary thread but yours may have been cross threaded sometime in the past and you've just caught the bad bit of the thread! You will have to get a T9 5 speed in it, just 3 screws holding it in.:)

Nice to have got it sorted though!

dasadrew

04-04-2009, 11:58

Just fired her up!!! :cheers::cheers::cheers:

Did a last minute distributor swap a couple of days ago. When flames came out of the carbs, I knew what I'd done wrong!! Quickly turned the dizzie around 180° and, after churning the engine over long enough to get air-free petrol up to the carbs, flatten the battery etc, it fired up after only half a dozen or so cranks (with battery charging inbetween :rolleyes:)

Bloody hell, those twin 44IDF Webers are very throaty and aggressive after 15 years of modern fuel injection cars!

It's a bit lumpy at tickover - can't quite remember if it used to be like that. Suppose it's OK considering it's got a big-valve, gas-flowed stage 3 type head, Group 1 cam etc. Smooths out above about 1700 r.p.m.

No leaks, no unusual noises. Am well chuffed.

graham John

04-04-2009, 14:14

congratulations...................

:wav::wav:

another milestone, bet you are well pleased,

cheeRS

Banishit

04-04-2009, 14:35

nice one andrew

grum

04-04-2009, 14:49

:cool:

pics please :)

RUDDY

04-04-2009, 14:57

Well done mate, nowt better than the first fire up :thumbright::thumbright:

Aled

04-04-2009, 15:00

Well done.....a video would be nice ;)

dasadrew

04-04-2009, 16:30

I'd asked a couple of mates to do a video, but they turned up late and I couldn't contain the urge any longer.

Have now just had a fright .... :eek::eek::eek:

Instruments aren't connected yet, so I was relying on the electric fan thermostat to tell me when operating temperature was reached. All of a sudden, the motor starts to really labour to keep going. All hell breaks loose, radiator cap pops and boiling water everywhere. Motor grinds to a halt and won't start again. Arrggghhh!!!!:eek::eek::eek:

Electric fan didn't come on because I hadn't connected the relay earth to chassis yet :rolleyes:. So now faced with pistons having welded themselves to the bores, made a cuppa and reflected.....

Er, could it be that the two pints of fuel I'd put in only represented half a pint of usable fuel, and that had been used up now? :confused::confused:

Topped up with more fuel, connected fan relay to earth. Starts and runs even sweeter than on the first go :thumbright: Panic over. Engine sounds seriously evil! :toma:

RS2000EXPRESS

04-04-2009, 16:56

dasadrew

05-04-2009, 17:03

Have never liked the idea of those plastic covers on the relay for hetaed rear window under the dash to be melting away as they do. Replaced mine with a modern type of relay with fuse

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/HRWRelayneu.jpg

Be aware though ! The Ford relay pin pattern is not the standard as is used today and since 20 years. To make it work, you have to swap the pins 30 and 86 (red wire and black/red wire). You can unlatch the spade connectors in the terminal block and refit them swapped over. Then, any new relay should work. Must be the same for the headlight relay and electric fan relay, but haven't checked them yet.

andym

05-04-2009, 23:15

Nice one...

RS2000EXPRESS

06-04-2009, 10:00

good idea!

dasadrew

12-04-2009, 17:57

Praise be to the Lord! Jaffa can see again!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_0988Medium.jpg

Just spent two hours trying to trace an earth/short circuit problem in the lighting looms. Found it at last - I DON'T BELIEVE IT! - it was a short within the H4 headlamp bulb itself. Both filaments worked, but had a short in them. Changed the bulb and everything is tickety boo.

So, just need to plumb in the instrument binnacle and then all the electrics can be signed off :thumbright:

Aled

12-04-2009, 19:07

Coming along a treat Andrew ....light at the end of the tunnel now :cool:

Chesney

12-04-2009, 19:22

looking real nice now, will you be bringing it over here to any shows at all, would be good to see it in the flesh.

dasadrew

14-04-2009, 18:54

Nose now going on. As it's been off the car for a few years and has taken on its own form, it will need a few days of persuasion to get it to fit into every corner without forcing it.

RH Headlight backplate needs dropping a few millimetres.

All headlights and blinkers are BNIB NOS Ford boxed originals.

At last it will stop the pesky neighbours asking if it's an Opel!

http://i221.photobucket.com/albums/dd284/dasadrew/IMG_0989Medium.jpg

Banishit

14-04-2009, 18:56

thats looking great now mate

68 Bullit

14-04-2009, 19:26

she,s looking very cool Andrew. Loved your web page , especially the car humor

Dave1800BDA

14-04-2009, 19:46

looks great andrew, nice to put all the new bits on,

Nipper

14-04-2009, 19:46

looking lush Andrew :cool: :cool:

Frosticles

14-04-2009, 20:06

Stunning Andrew :):):)

paul mex

14-04-2009, 20:24

"At last it will stop the pesky neighbours asking if it's an Opel!" PMSL :p
Now Thats really starting to look really smart :cool:

wiggyrs

14-04-2009, 21:18

Looking very nice Andrew :cool::)

grum

14-04-2009, 21:21

very :cool:

RS2000EXPRESS

14-04-2009, 21:28

Looking Spot-On Andrew.:cool:

dasadrew

14-04-2009, 21:31

Cheers for all the comments chaps! :thumbright:

dasadrew

15-04-2009, 18:43

Carried on aligning the nose tonight. Ended up using quite a few shims on the top fixings but what the hell. Considering that wings, scuttle grille, bonnet and front panel all got changed, I mustn't grumble how the alignment turned out. Probably wouldn't get past Audi quality control though!

Headlights aligned and I couldn't resist popping in some old headlight surrounds - they reall change the look of the car I find.

Little eBay package arrived tonight - brand new in box ignition lock with keys. Just need to recode the boot and door locks to match now. Anyone got any tips on that? Does the key number help? I bought a recoding set from Ford ages ago with a set of tumblers and springs. Do I have to dismantle my new lock to see what combination is in there?

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_0995Medium.jpg

RUDDY

15-04-2009, 19:21

Get the ferry booked for the Lakes son, it'll be ready in time :D looking sweet :thumbright::thumbright:

andym

16-04-2009, 09:32

Andrew your car is just stunning....keep up the good work....

ASHLEY

17-04-2009, 22:29

Some nice work :thumbright: Looking good.

dasadrew

10-05-2009, 18:25

Started putting on the vinyl roof today. Two mates I had line up to help at the weekend dipped out, so I pressed on alone.

Having been stored for about 20 years, the thing needed a bit of pulling into shape and one of the seams ended up very slightly ****y.

I found it pretty tricky in places and that contact adhesive is a barsteward and always seems to stick when you don't want it to. I bought the proper stuff for vinyl car rooves too and it certainly didn't do what it said on the tin!

Anyways, all looks okay and just the details to finish off. Hope it's not going to blow bubbles when sat in the sun as the rumours go.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/VINYLROOFMedium.jpg

Miniliteman

10-05-2009, 20:13

Vinyl roof ... :eek: ... why?

dasadrew

10-05-2009, 20:17

Cos they look fab!!:thefinger:

Blower

10-05-2009, 20:34

Cos they look fab!!:thefinger:

:yeah: Agree

paul mex

10-05-2009, 20:49

Vinyl roof ... :eek: ... why?
Me too :rolleyes:
Each to there own tho, I still love the color/car :cool:

RS2000EXPRESS

10-05-2009, 22:44

Not many orange ones around with vinyl, will look good!:cool:

dasadrew

11-05-2009, 06:05

Not many orange ones around with vinyl, will look good!:cool:

Here's one nicked from this site

http://i221.photobucket.com/albums/dd284/dasadrew/OrangeBVRRS2000.jpg

X-Pack from "Clockwise"
http://i221.photobucket.com/albums/dd284/dasadrew/ClockwiseRS02.jpg

RS2000EXPRESS

11-05-2009, 09:16

Here's one nicked from this site

http://i221.photobucket.com/albums/dd284/dasadrew/OrangeBVRRS2000.jpg

X-Pack from "Clockwise"
http://i221.photobucket.com/albums/dd284/dasadrew/ClockwiseRS02.jpg
Absolutely Lush aren't they?.........and you can see the join at the top of the pillar on the top piccy!

taffr

11-05-2009, 09:26

i agree will look wicked:cool:

RS2000CUSTOM

11-05-2009, 10:08

Just need to recode the boot and door locks to match now. Anyone got any tips on that?

Very easy to do.

I suggest you get hold of a couple of old locks - strip them down and keep all the tiny springs and brass tumblers

There are 4 variants of the tumblers and the locks are a combination of the 4 so sort into 4 groups to help when rebuilding lock barrells.

Note - Each tumbler has a tiny spring to go with it (all psrings are the same)

Using a stripped barrel put any tumbler in the first slot to be acted on by the key - when key is pushed in and the tumbler is flush with barrell then that is the correct tumbler - if not try another tumbler and so on

Make a note of your combination and repeat for all locks

Rebuild locks

JOB DONE !

p.s. its a lot easier to do the job than to write an instruction book on how to do it - lol

dasadrew

11-05-2009, 14:42

Thanks. I did them all last week after self-learning the method - exactly as you have written!

dasadrew

12-05-2009, 19:32

The deed is done!

It was handy having bought the hockey stick finishers and two new gutter trims at the Ford dealer 18 years ago! Even had some black rivets for the "C" Pillar trims. All turned out fine although there was more to it than I thought. I stretched the "A" pillars down a bit as I don't like the way the originals finish just short of the windscreen rubber and in line with the gutter trim end.

"C" Pillar trims got a freshen up with Auto Glym Bumper Care - great stuff :thumbright:

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/VINYLROOF1Medium.jpg

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/VINYLROOF3Medium.jpg

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/VINYLROOF4Medium.jpg

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/VINYLROOF2Medium.jpg

Dave1800BDA

12-05-2009, 19:40

looks bloody lovely andrew, nice detail

vinny

12-05-2009, 19:55

looks bloody lovely andrew, nice detail

took the words out of my mouth

Aled

12-05-2009, 20:18

Very very tasty Andrew ;)

Chesney

12-05-2009, 20:50

a real minball is that, well done

andym

13-05-2009, 13:44

Just stunning as always, Keep up the good work.

Banishit

13-05-2009, 18:02

your just an artist Andrew, and perfectionist, hats off to you and your skills

enduro

13-05-2009, 18:21

superb!!!!,my favorite colour and the vinyl roof looks perfect,top build ,wish i had your eye for detail and your patience.

dasadrew

21-05-2009, 18:50

Front and rear screens in. Parcel shelf refurbed. Rear seat belts going in now - they weren't fitted before. Speakers look less obtrusive in real life than on the pics. Chose the most sober ones I could find. Decided to go the parcel-shelf route rather than door cards. Have got another uncut parcel shelf in case I have a better speaker idea sometime.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_1164Medium.jpg

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_1166Medium.jpg

Joe

21-05-2009, 19:32

Like the vinyl roof Andrew. It looks great.

CheeRS,

Joe.

Miniliteman

21-05-2009, 19:40

Like the vinyl roof Andrew. It looks great.

CheeRS,

Joe.

Must be an english thing ...

dasadrew

21-05-2009, 19:44

TBH, I'm not ENGLISH !;)

Frosticles

21-05-2009, 19:49

Roof looks amazing Andrew. Always been a fan of these. :)

wetandwindy2

21-05-2009, 19:50

you done a really nice job there mate,and the vinyl roof perfect ,i think it goes well with that colour ,was it hard work to fit the roof (vinyl)

dasadrew

21-05-2009, 19:54

you done a really nice job there mate,and the vinyl roof perfect ,i think it goes well with that colour ,was it hard work to fit the roof (vinyl)

Not so much "hard" work, but very laborious. The real proof apparently comes when the car stands in the sun, as any little spots which weren't completely glued will become little bubbles :eek::eek:.

I would have preferred a team of professionals to glue the large roof section into place and then leave me to finish off the details. However, there were no outfits nearby, the car didn't have glass, and wasn't registered.

Miniliteman

21-05-2009, 20:32

TBH, I'm not ENGLISH !;)

Let me refrase, must be a United Kingdom thingy ....

dasadrew

21-05-2009, 21:23

Let me refrase, must be a United Kingdom thingy ....

Ahhh, go stick yer finger in a dyke! :D:D:D

dasadrew

08-06-2009, 06:52

Still some progress being made, but got slowed down by lots of niggly upholstery issues.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_1174Medium.jpg

Interior looks better than the flash photo shows, as every grain of dust reflects the flash!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_1175Medium.jpg

Try as I might, I couldn't get the vinyl back into the recess of the RH rear trim (armrest) so will be looking out for a minty-minty one! The vinyl had just shrunk and hardemed too much - ruined another one with heat gun trying to repair it.

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_1176Medium.jpg

Refreshed the badges with 2-pack satin black. Have filed off all the pins and will stick them on with double sided badge tape to avoid a few rust spots!

http://i221.photobucket.com/albums/dd284/dasadrew/rs2000/IMG_1178Medium.jpg

paul andrews

08-06-2009, 07:14

lovely stuff m8

mike77cos

08-06-2009, 08:04

Looking good

dasadrew

08-06-2009, 08:33

lovely stuff m8

Not quite in your league though m8! :notworthy:

Banishit

08-06-2009, 09:54

looking great drew

this thread will be longer time taken than Graham Johns :rolleyes:

RS2000EXPRESS

08-06-2009, 10:55

It's looking great Andrew!.........the colour and roof combination are stunning 70's!:cool:

grum

08-06-2009, 11:42

graham John

08-06-2009, 11:51

coming along well there andrew

cheeRS

dasadrew

08-06-2009, 12:22

:cool:

TOP TIP - how about getting a needle syringe and filling it with contact glue to get behind the vinyl - worked a treat on a 'lose' old steering wheel rubber for my old mk1 mexico ;)

TBH, that's exactly what I've been doing! I also peeled back the vinyl and got in via the ashtray hole too. You have to go in from the back, however, as the tiniest hole in the vinyl rips open when you stretch it.

Problem is that the vinyl is so taught that, although the glue sticks it, it then peels off the top layer of cardboard from the backing due to the tension. I've had one baking in the sun, I've used hot air gun to stretch the vinyl, but it's simply lost too much flexibility and size over the years. Sort of like the bulkhead pads - the bitumen there dries out and you can't reverse it.

Strangely enough, the LH side ones are all OK and the RH side ones are all knackered :confused::confused: