Mk1 Fiesta Zetec - Project Welsh & Proud

[WelshRS]

lol @ taffr

not done as much as i wanted this week had a bit of a set back last monday evening with the angle grinder!!!! was grinding of some rust of on the sill when i stumbled on the lead and the grinder caught the sill and the grinder kicked back hitting me in the mouth/chin, 4.5 hour wait in casualty and a hole in my chin that had to be glue, i'd cut all the inside of my lip and badly bruised, my teeth were ok thank god!!, only now starting to get used to eating and drinking properly, very painful

not gonna happen again, got a face mask now - a lesson learned

still trying to remove all tehe underseal from the car a messy and horrible job, got the flatter surfaces of ok, just all the nooks and crannies to do now, getting there though hoping to get it all taken off by the weekend.

Chris

[RS2000EXPRESS]

Great job you're doing there m8. Nice to see something different from the usual Escy on here!

Tim.

[WelshRS]

Been busy the last week stripping of all the underseal and waxoyl not a nice job, most of its of just the awkward bits left, i've finished of welding up all the drain plugs, removed all the unecessary brackets, brake pipe clips, exhaust brackets, fuel tank mounts, handbrake captive nuts.

also had to add a section to the chassis rail where the bolt comes through for the roll cage, when i drilled the hole through it came out right on the edge no room for nut to go.

started to repair the bootfloor / panhard rod mount, floor bits sorted just need to reconstruct the chassis rail bit (roll bar mount) section, unsure of how it should look as it was rusted through,

welded in the 2 seat belt mounts gonna weld in another two for the fifth point on harness - prob never use it but thought i might aswell as it while i'm doing it.

gonna get an exhaust back box this week so i can start making the cut ouy for the side exit exhaust.

never looks like i've done enough but it never does - few pics below

Chris

[WelshRS]

Side Exit

Been busy this morning working on my side exit exhaust, bought a fiesta rs1800 back box, its a bit on the large side but should cope ok with the 2 litre zetec at least i won't need a middle silencer now can have it straight through from the manifold

Not as easy as first thought was hoping it would all line up ok and i could use a straight bit of pipe for the tailpipe but the chassis rails in its place, just gonna have to angle it past the rail then straight out got a length of the 2" to do it.

I've had to fabricate all new straps for the box and weld new mounts for it so it can be fixed to the underside of car, only part i could use new was the rover mini exhaust bobbins, gonna get some polybush ones once its all painted up.

Next job is to cut a hole out the side of the car so i can insert the tunnel that i've pre made from a fiesta mk3 fuel cap repair panel and a piece of mild steel that i shaped into a tube and welded together, also got to cut the pipe going into the exhaust and make a bend so it turns towards the tunnel.

Don't know why i keep making work for myself i'll never get the thing sorted if i carry on this way!!!!!

Chris

[fast eddie]

cool!, keep the pics coming

[enduro]

just read through this thread,some work being done,,very impressed,heard a grinder in the chops aint good for you,had a few cuts from cutting discs and welding burns,but never tried that one.keep at it buddy ,shes going to be a credit to you.

[WelshRS]

literally blood sweat and tears, and a car crash in my zetec s which has stopped me working for the last two weeks, its certainly gonna be an eye catcher especially if i do end up painting it le mans green

Chris

[WelshRS]

exhaust is mounted and tailpipe which needs cutting down a bit think it'll fail an mot with it that long

gonna get a carbon shround to round the hole and on the arch to stop the heat affecting the paint, the tailpipes gonna be wrapped anyways
tunnels nearly finished just got to grind off some welds inside then smooth of and round over the edges

another job nearly to tick of the list.

Chris

[ASHLEY]

Looking good . Some nice work done there m8

[WelshRS]

Long over due for update i think, after going to the Rally Day at Combe last weekend i came home with a lot of ideas and inspiration to get cracking on getting the shell a it further forward.

there was a yellow mk2 escort shell that had be prepped for rallying, and they'd welded in these spacers onto the floor for fitting the footrests, i was always gonna put alloy footrests in but was just gonna bolt them straight to the floors so first thing i did this week was get one on order

so spent all of this morning making up 8 spacers from 1" tubing and caping of the top and welding in a nut on the inside, ive welded them to floor and the foot rest now bolts straight to that will get some nice stainless socket headed bolts for them when the insides all painted, the company i got the footrest of doesnt make a drivers side one so ive got them to make me one to match gonna get them powdercoated satin black to match the black/white theme im doing for the interior.

the underside of the floor is nearly all in etch primer, going into work tom to finish of the last bits with etch primer and start on seam sealing all the joints ready for a nice coat of stone chip primer on tuesday then leave it a few days to go off and then my mates coming on sat/sun to give the floor a nice shiny coat of diamond white, really cant wait to get that done.
going on hols the week after the floors painted so by the time i get back the floor should nice and hard, i can then get the shell turned the right way up and start getting the cage out and get all the inside ready for paint.

Chris

[taffr]

good graft chris, glad the trip to combe tripped the interest switch again, can't wait to see it in pent next week

[WelshRS]

still having thoughts of le mans green though, but i'll regret it if i dont do it diamond white least the paint supplier keeps diamond white on the shelf cheaper that way too

Chris

[Andyc]

come on chris get this tub finished

[WelshRS]

Finally got all the underseal sorted on the floor and two inner arches, took ages masking of then brushing it then removing the tape, maybe went a bit too far cutting circles on the computer saving me masking up a circle lol, gonna soft the edges with wet n dry paper dry and remove some of the glue and then its all ready for its stone chip primer tom night - cant wait for that and then a nice coat of Number 1 shade diamond white on the weekend

the pic with all the ladders is my way of making a temporary spray booth gonna cover that in plastic, more to help save the dust getting everywhere

Chris

[taffr]

loving the ladders chris, you gat enough there, hope health and safety aren't watching, can't wait to see it in pent, may be down this weekend, castle combe sorted your head out son, deb says see you sat so you can finish off the job in her mums bedroom