My flat front RS build (not rebuild!!)

[mk1rally]

After much grunting, grinding and welding I finally got the exhaust to fit better. It's managed to go down to a single box because the fit of the twin was bad. The cherry bomb was hitting the floor plan when the system was high enough not to ground out and the axle was going to hit when the rear suspension was fully flexed. So i decided to fit it as a single box and see how loud it would be (very I bet!!). Still, managed to tuck it right up and there is plenty of clearence around the axle/shell.

IMG_0762 by jerrythegerman, on Flickr
It fits nice at the rear valance too.

IMG_0764 by jerrythegerman, on Flickr
Better a little loud than banging and crashing about me thinks. I may have to re think a additional box in the future if needed.

Also had a "playing about" moment and decided to sticker it up a bit. Shouldnt waste time on that but sometimes I just wanted a break from crawling around under it!!


IMG_0766 by jerrythegerman, on Flickr

IMG_0765 by jerrythegerman, on Flickr
Just getting on with the final wire up of the fuel pumps and I should be in the position to fire it up.

Still plenty to do but bought a diesel heater for this winter so should'nt be freezing my knackers off this winter!!

[LOUIE]

Priced up shipping for to escorts to oz mate, you no u want to

[Mikethepanel]

Looking good dave

[mk1rally]

Cheers gents, go on rob how much?

[kas750]

Looks good that Dave..I like the stickers as well.I bet theres more on it by the time you have finished though!.

[cossie si]

Looks great. Whats the small reservoir in the boot? Is it a breather for the axle?

[mk1rally]

Yes Si, used a spared brake bottle.

[mk1rally]

Wey hey, started to old girl today! All electrics work a treat bar the dash face lights and the oil pressure gauge in not registering any pressure, but there is as I made sure of it before connecting the coil. Added water and antifreeze and once warmed up and settled, it idled at around 1k with no silly noises.

I'm a very happy man. The exhaust is not as loud as I thought, but I'm sure it carbon up!!

I guess I won't get much chance to play over next couple of weeks but it running as cured my fix for a while!!

[mk1rally]

No pictures as yet, but to follow later.

I've decided whilst in this state, the middle box has to be added but I had a spare rear box of the same type of Ashley system.

Managed to work this in and it's brought the sound levels right down, ideal for longer events as it will keep me sane!! It shouldn't cause too much issues with gas flow either.

I now need to tuck the system up a little more as it's almost level with the chassis rails!! not great for ground clearence in the middle.

Because of using a rear box for the middle section, I'll may need to raise the floor pan slightly in the rear driver foot well, not much but enough to allow me to raise the silencer. There is a drain plug/ steel bung that just juts down enough to cause the challange. I may well slot the floor pan and raise it slightly.

The other option/combination is to raise the suspention as its on slightly less cambered springs and 1.5 inch lowering blocks, it's fairly low!!

[Mikethepanel]

Woohoo nice one
Now get it used! Lol

[Davecos4x4]

very nice work.

[mk1rally]

Spoke to the Squires and it seems I shouldn't need the lowering blocks, so I've took them out and we have a lovely 7.5 inches between the rails and the floor when on 185/60/13s.
Talking of wheel's, I recently had a swap around and seeing a fair few of the events I plan to use the car on limit the width to 6 inch, I've gained a few more wheel tyre combinations. Thanks To John Savage to machining to group 4 and made a lovely job of it.
I also have bought a few of these (8 in fact) Minilite Sports rims which I intend to swap the A2's onto.

IMG_0811 by jerrythegerman, on Flickr
I love the colours!!

i've also been working on the brake's and after taking idea's from the works escort in details book, I've used a FF drop link with a rose joint to connect the cylinder to the arm. It still allows me to use the original center belt mounting points and puts the elbow wrecking stuff out of the way in theback. It works a treat, well mechanically. You can see the floor pan mod in the back ground that allows me to fit in a rear box as a centre, keeping the noise down a bit. It needs a clean out too!!
IMG_0815 by jerrythegerman, on Flickr

Just the rear plumbing to do now on the brakes.

[Skids]

Spoke to the Squires and it seems I shouldn't need the lowering blocks, so I've took them out and we have a lovely 7.5 inches between the rails and the floor when on 185/60/13s.
Talking of wheel's, I recently had a swap around and seeing a fair few of the events I plan to use the car on limit the width to 6 inch, I've gained a few more wheel tyre combinations. Thanks To John Savage to machining to group 4 and made a lovely job of it.
I also have bought a few of these (8 in fact) Minilite Sports rims which I intend to swap the A2's onto.

IMG_0811 by jerrythegerman, on Flickr
I love the colours!!

i've also been working on the brake's and after taking idea's from the works escort in details book, I've used a FF drop link with a rose joint to connect the cylinder to the arm. It still allows me to use the original center belt mounting points and puts the elbow wrecking stuff out of the way in theback. It works a treat, well mechanically. You can see the floor pan mod in the back ground that allows me to fit in a rear box as a centre, keeping the noise down a bit. It needs a clean out too!!
IMG_0815 by jerrythegerman, on Flickr

Just the rear plumbing to do now on the brakes.

Dave are you fitting seat rails as where you have the battery cable and pipe will be in the way when it comes to welding the reinforcement plates ?
Mark

[mk1rally]

Hello mark, it's not going to be a stage car, I'll be using strengthened original fittings.

For now....! It's being used for targa (hopefully) or European road events.

[mk1rally]

Painted up the cylinder bracket after welding some bolts into it to aid install/removal. Finished off the handbrake and fitted the fly-off kit. Fitted the rubber boot and plumbed it up. Very pleased with it and now just need to extend the original steel rod for the mechanical handbrake on the atlas.

sec2 by jerrythegerman, on Flickr

securedownload by jerrythegerman, on Flickr
Going to make a ally box to protect the pipes and the trim a piee of carpet that will sit over the lot (half way up the rod) to keep it tidy.