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My flat front RS build (not rebuild!!)

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  • My flat front RS build (not rebuild!!)

    After a bit of mythering, thought I'd grab some time (its too cold in the garage -4!!) to post some photo's of my build.

    I'll make no appologies, this is a build of a originally very knackerd RS2000 to the road, in fact the original car was so knackered, I reshelled it, arched it, changed the colour and intend to enjoy it.

    RS police - Before you moan about restoring it, it wasnt economical to do so. It was a rally car, had a very hard life and TBH, you could have easily sunk 20k sorting the shell out with NOS panels and paint/time. I have restored enough cars to know what I want from it and is important to me. A good strong shell is key, not years of continuely patching it up and I had my eye on a mint LHD one that would do the job. I do appreciate the originals too, and if you have one or one that can be recovered, that's great and you were lucky..I wasnt so lucky but it was what doable within my budget and what I wanted to do with the car. TBH, I would not have arched it or changed it's colour if it was a good example, as per my other car, my Mini. A few on here have seen that and will tell you it's a lovely rebuild.

    I'm a firm believer of using them, not polishing them in the garage so a reshell was fine for me. If I ever sell it, I will be clear it was the case, not try and pass it off as its original shell. Its on print in here, see so I can be called on it!!

    Justification over!!

    Ok, so in my youth, my Dad and my Uncle both used to run cars in the motoring news championships, and local event's up here in the North West of England. I sent the 70's and early 80's brewing up, cleaning numbers, changing wheels, Driving service vans (sorry officer, only a few miles and I look much older than 15!!), refueling and general od jobs before getting to drive at a later date myself on Mull and the likes.

    This Escort is to be built as a bit of replica of the cars they had, but not specifically the same. Mostly period bits and to be used for runs around here, track days and maybe some longer distance tour type stuff. This is because the RAC/MSA went and banned 4 chokes on a 4 pot engine, arches, non FIA/MSA dates stamped seat's/belts so there is not really a modern class for this car to compete in. I already have another car to do this anyway.

    My uncle died last year of the big C and my Dad dragged the pictures out of those heyday's and said it would be good to do/have something like those old barking escorts again....so i decided that was a nice thing to do and its made my Dad (approaching his 70's) a very happy man and he can't wait to have a ride out in it!! It's lovely to see him excited.

    Pictures to be uploaded

  • #2
    Look forwork to seeing the pics
    I also competed in the MN events and recall the greats nights out on the likes of the illuminations and the RL Brown
    sigpic

    Back with a MK1

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    • #3
      Ok, so here's the shell as it started out.


      022 by jerrythegerman, on Flickr

      It was a 96k kilometer (less than 60k miles) car from Northern Sweden. They dont use salt up there apparently and tend to only bring them out in the summer. It had a sump heater in it that you plugged into the mains to keep the oil warm and a additional plug that I can only presume was for a heater internally. Apparently it was a 1 lady owner and it showed. The trim was lovely and apart from a dented rear bumper, it was in geat condition with very little wear. It has the original ford tool kit, rubber mats, mud flaps, jack and bag.

      The shell needed a small (2"x2") patch at the bottom of the tyre well and about the same size on a chip on the front off side wing. I cut out the rot and let these in, lead loading after to ensure a good seal. The rest of the shell was factory paint, even the underside had the chassis balck showing on the floor pans. It had/has a thick sealer in the arches that seams to done its job. Thats it.

      The roof had peeled and had been painted with red lead to stop it getting worse until it was resolved, but not dented or rotten.

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      • #4

        036 by jerrythegerman, on Flickr

        I'm sure this has been covered off before so I will show you a few of the progress shots.

        After marking up and drilling the rear arches, I cut out the outer lip and the inner well to allow me to raise the height of the tub. The black line is the seam where the arch rivets to the body. The outer was cut level and in profile with the inner arch -10 mm which I then bent up carefully to make a lip to attach the new inner tub too. nerve racking stuff. My dad came down and talked me through it plus I surfed the net a fair bit too befor making the cuts!!

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        • #5
          The arches were then etched and painted body colour before being seam sealled and rivited to the body. Helps stop disimilar metal corrosion.

          I temp put on the new axle to make sure all was clear with the rims. Its a 3 ltr capri atlas with a ZF LSD, 4.6 CW and brace/skid. Built by the squires. Oh and it's still on drums for now!! This gave me the positions for the Panard tower and antitramp brackets (we are running a back seat as he did!).

          I tacked these in place, took off the axle and welded them up proper. I also strenghthend the boot floor up where the tower comes through and mad a plate to cover it so it look right.

          Back went on the old axles and wheels for paint.

          028 by jerrythegerman, on Flickr


          045 by jerrythegerman, on Flickr

          The trim holes were carefully welded up (min heat) with a copper bar behind them and etched.

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          • #6
            This was it with the big axle on.


            048 by jerrythegerman, on Flickr

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            • #7
              Nice, love an arched MK2, keeps the pics coming

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              • #8
                Everything was carefully stripped out of the car as some of it would be reused again (trim panels mostly)

                I then got the turrets together. Now although the rounded ones look nicer, cars my dad and his mate's ran had square ones, they looked (too me) easier to fit and were cheaper!! I was quite happy to use that as a excuse!!

                So I marked it up by using some diagrams from the squires and cut the inner arches and parcel shelf. Tacked the bases in and then with the help of a ratchet strap, got them in the right position/incline and welded them in place. I made small fillets for the parcel shelf area and tacked all that back together.


                046 by jerrythegerman, on Flickr

                Once I was happy with that, i managed to get a RHD dash from GS Escorts (cheers Graeme) and cut out the old one. Along with the pedal box holes and steering coloum holes, we were ready to go after a clean out and final prep.

                Andy at Newlook custom's convinced me he was going to move the pedal box strenthening plate and fill up some of the LHD holes.

                It was loaded onto the trailer and taken to paint.

                It was 3 months into the build, working 6-7 hrs a week and the odd day at the weekend.

                058 by jerrythegerman, on Flickr


                057 by jerrythegerman, on Flickr

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                • #9
                  I forgot to add, I added the RS specific panels to the shell and gusseted the rails, cut out for the rad and added the rad top panel and bottom. The shell was then welded up as per the escort prep book. I also cut out the rear valence to allow me to raise the back box a little.

                  Ok, whilst at Andy's he moved over the pedal box plate that's inside and welded up the old holes and made them good. Made good the areas along the sides where the chrome trims were and generally squared it all up.

                  The blokes a perfectionist and he spent a fair while sorting the swage lines and making sure the door, boot and bonnet fits were just so.

                  Once he had done that, he painted the inside of the doors, boot and bonnet, also the complete boot area and engine bay.
                  067 by jerrythegerman, on Flickr




                  085 by jerrythegerman, on Flickr
                  066 by jerrythegerman, on Flickr

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                  • #10

                    086 by jerrythegerman, on Flickr

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                    • #11
                      I've alwways like diamond white and it was the colour of my first and second escorts back in the day (it was 20 years since I've had one!!) so the shell being white anyway it worked out fine. The original RS was Red and then Black and then a few other shades at some point!! I dont think it was ever white!

                      I wanted to replicte some of the period schemes and not create a works replica, its been done and I love them but like I said, my Dad, uncle and chums never had anything so fancy.

                      I liked the flash on the Cossack cars and loved the colour of the 77 works ones. I ended up drawing a few pictures and colouring them in (a ideal thing to do with your 2 year old!!) and when I had a load of mates over for a meal, asked them to choose. Well the design was pretty much the one I would have picked and I simply handed this over to Andy with the colour codes and bit of a chat. When I got it back, I wasn't sure but its grown on me and I love it now the shell is coming together. A bit different but period enough, not to fancy.

                      My Dad said that they just masked them up and painted them, not flatting them off so there was no ridge between the colours and then I read that the works cars were hand painted, So that was good enough for me. So there is a ridge but that's ok. I did'nt paint the rear arch as it would have been less of a pain to change should it have been clipped (apparently).


                      089 by jerrythegerman, on Flickr

                      092 by jerrythegerman, on Flickr

                      091 by jerrythegerman, on Flickr

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                      • #12
                        I got the shell back just after christmas. Took the old axle off and started on the underside at the rear. I scrubbed it back, added a coat of stone chip and 3 couats of white hammerite. Obviously masking off the top coat. same on the rear arches and some way on the back of the floor pans. Also where I replaced the diff panel (for the bigger pigs head)


                        126 by jerrythegerman, on Flickr


                        127 by jerrythegerman, on Flickr

                        Once that was done, I bolted on the atlas axle and the new rims/tyres and spun it round ready for the front.


                        130 by jerrythegerman, on Flickr

                        I love that angle!!

                        I did the same to the front arches and under the front foot wells. Then I built up the struts (cheers cossi si) with GP4 hubs, Willwood calipers (Cheers Louie/Mikethe panel) and bolted the whole lot up. Not a great photo, must have been a cold Iphone or me shivering!!

                        137 by jerrythegerman, on Flickr

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                        • #13
                          That cage has gone in but is not bolted down yet. It was to get it out of the way in the garage and I want to fit it when the engine is in place and the shell is stressed as it would be on the road (within reason). Next up was the wiring loom. I have the original LHD one and the original RS2000 one. Its been a bit butchered at some point but with a bit of thinking, I think I have sussed it. the connectors are not damaged and it doesnt seem brittle. I would have loved to replace it but they dont make them new due to the rubberised connectors (apparently). I had to bolt on my lamps because:

                          1. it gets me a bit giddy!!
                          2. gives me a idea where I want the extra wiring/relays for the additional loom I will have to make.
                          3. it gives me the opertunity to make brumm brumm noises when nowbody is listening!

                          142 by jerrythegerman, on Flickr


                          141 by jerrythegerman, on Flickr

                          Ive got a fair few bits to go into it.

                          Nice Mike Stewart 2.0 pinto from mike the panel (RL22, twin 48's and gp 1 head) though I am considering a CNC head,
                          BGH type 9 box (still also got the original RS box too)
                          Export tank (my dad said he used Capri ones but I prefer the look and location of this one) cheers Andy.

                          On the inside I've got a set of Scheel RS1800 buckets and a standard rear seat (I used to ride in it as a kid on my dads!), Spingalex rim, Halda twinmaster, full set of carpets. Cheers Darrell.
                          I rember removing the carpets and trim out on a Friday afternoon before they went on event. When he was a bit short, it was the only car so he used to take me to school or take his tools to work in it (he's a retierd builder) other than that it was his company Snapes transit van (anyone remeber them, dark green?), brushed out and loaded up for the weekend!!

                          Once the electrics are sorted and I am making up alloy panels to relocate the fuse box inside, I'm onto the brake plumbing. Should be fun.

                          Hope you are enjoying the pics as much as I am enjoying the build.

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                          • #14
                            that looks spot on, nice to see a freshly built car getting done, cracking job

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                            • #15
                              looking good
                              sigpic

                              Back with a MK1

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