Mk2 Escort Group 4 Rally Car

[Springerdinger]

Some very tidy and straight welding ,
Can I ask what thickness steel did you use on the Y shaped assembly?

Cheers

Chris

 

[rallyreturn]

Some very tidy and straight welding ,
Can I ask what thickness steel did you use on the Y shaped assembly?

Cheers

Chris

The tidy welding was done by Sean at Rally Weld who fabricates all the bits required to build a GP4 shell, my welding is not so straight!!!!!! I wish I could weld like him but he has 25yrs more experience than me. His Aluminium Tig welding is just as good, he really does make it look so easy when you watch him welding.

http://www.rallyweld.com/

The main box assy is 3mm and the gussets are 1.5mm.

 

[rallyreturn]

Finished off the Panhard assy today, now bullet proof.





Uploaded with ImageShack.us





Uploaded with ImageShack.us



I've also done some seam welding around the front strut areas and re-did the chassis rails as the welding was crap, just like the rest of the previous owners work!!!!!





Uploaded with ImageShack.us





Uploaded with ImageShack.us[/URL

 

[rallyreturn]

I've spent a lot of time grinding down old crappy welds and trying to make nice new welds, not always successful but still better than they were.



I picked up some sill stand tubes from Sean at Rally Weld last Week so made a start on them today, only managed to get one done and that took about 5 Hrs.





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us

 

[rallyreturn]

All four sill stand tubes now welded, next are the seat mounting tubes, another trip to Rally Weld!!!!!!





Uploaded with ImageShack.us





Uploaded with ImageShack.us

 

[kennedy8585]

Look good and what are you using to cut sheet metal?

 

[rallyreturn]

Look good and what are you using to cut sheet metal?

Cheers!! I use a 4 1/2" angle grinder with 0.8mm cutting discs from screwfix. Wow just noticed that they are on offer at the moment so I'll be getting a few packs tomorrow.

http://www.screwfix.com/p/flexovit-ultra-thin-metal-cutting-discs-pack-of-5/71334

 

[kennedy8585]

Cheers!! I use a 4 1/2" angle grinder with 0.8mm cutting discs from screwfix. Wow just noticed that they are on offer at the moment so I'll be getting a few packs tomorrow.

http://www.screwfix.com/p/flexovit-ultra-thin-metal-cutting-discs-pack-of-5/71334

I'm looking for sometime like this but i don't think i find these in Kanada. What size gauge sheeting metal are you using on vehicle??

 

[rallyreturn]

Called into Rally Weld yesterday to buy a few more fabricated parts, Sean was busy spanner checking his MK2 for the plains Rally next weekend but still took the time to fabricate a jig to make me a tow hook for my car which only cost a few pounds, CUSTOMER CARE AT IT'S BEST, Highly recommend Sean at Rally Weld, so if you need anything for your Escort give him a ring, you wont be dissapointed.





Uploaded with ImageShack.us





Uploaded with ImageShack.us





After talking to Sean I decided ro seam weld around the Splash panels and floor pan, passenger side done.





Uploaded with ImageShack.us





Uploaded with ImageShack.us

 

[rallyreturn]

I'm looking for sometime like this but i don't think i find these in Kanada. What size gauge sheeting metal are you using on vehicle??

All repairs have be done with 1mm sheet metal.

 

[rallyreturn]

Drivers side seat mounting tubes now welded in place, I'll need to go back to Rally Weld to do the co-driver side because I cut one tube too short!!!! who said "measure twice cut once".





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us

 

[rallyreturn]

Now welded in the Co Driver seat mounting tubes, (slightly lower and further back).





Uploaded with ImageShack.us



I've also cut out metal from the rear wheel arches as these areas were damaged when I cut off the roll cage strenghening plates, butt welded new metal, not worried about strengh as the new cage will be turret mounted.





Uploaded with ImageShack.us











Uploaded with ImageShack.us





Also cut off the horrible strut brace brackets, and my next job is to weld in the new ones that I bought as a complete strut brace kit from Rally Weld.





Uploaded with ImageShack.us





Uploaded with ImageShack.us

 

[rallyreturn]

Spent all day fitting the new Magnum wings, only tack welded untill I'm completely happy with the full front end build.



I'll be fitting the arches next and then some final fettling to get the bonnet shut lines right.





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us

 

[rallyreturn]

Wasn't happy with the shut lines so re-fitted both wings, and took more time with door adjustment. Much better now so I got round to fitting the front arches and spoiler, just needs riveting and seam sealer when I have more time.





Uploaded with ImageShack.us



Gaffer taped arches and spoiler, them marked out the wing for cutting.





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us

 

[rallyreturn]

Finished off cutting the wings and the front panel to make sure there is plenty of clearance.





Uploaded with ImageShack.us





Uploaded with ImageShack.us





I made a dolley so that I can get the shell out of the garage for the 1st time in over a year and a half.





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us



I've spent hours wire brushing the old filler from the front arches and spoiler, countersunk the rivet holes, removed the burrs, etched primed and now ready to fit when I can find the time.

 

[Tupers]

Love the work you've put into this, very tidy indeed.

 

[rallyreturn]

Front arches and spoiler are now riveted on, had to improvise using countersunk screws and nylock nuts in some areas as these parts were taken off the old wings and front panel and some of the fixing holes were just too big for rivets.





Uploaded with ImageShack.us





Uploaded with ImageShack.us





Uploaded with ImageShack.us





I also got round to welding on the strut brace brackets.





Uploaded with ImageShack.us





Uploaded with ImageShack.us





I need to weld on the heater bowl and scuttle panel next. I've managed to repair the scuttle panel but the heater bowl (plenum chamber) is beyond repair due to the previous owner cutting it out to fit a coil and the brake reservoirs.



ANYONE HELP WITH SELLING ME A HEATER BOWL!!!!!!!!!!



If not I'll have to bite the bullet and buy new from Express Panels at approx £160.





I want to fit the rear arches so it looks like I'm getting somewere. I made a slide hammer to pull out some dents so I can start the bodywork.





Uploaded with ImageShack.us





Uploaded with ImageShack.us

 

[rallyreturn]

Gone a step backwards!!!!!! I wasn't really happy with the front spoiler, it was too high and so the sides drooped instead of being parallel with the ground. this is how the previous owner had fitted it as I used the same holes in the arches, I did try it lower but it didn't overlap the front of the arches.



Was going to live with it but somebody pointed it out on another forum so i have to change it. Already drilled it off but the holes are now far too big to rivet. I've welded up the holes in the front panel and ground down, just needs a skim of filler.



I was thinking about re-fitting it by drilling between the existing holes and then filling the large holes with filler, I'd also have to add metal to extend the arches, as I have no way to weld Aluminium this would be in steel, but not noticeable with filler in the join and it's only a small section. I would also have to straighten the spoiler edge lip as it is too short to wrap around the back of the arches.



I'll probably go plan B and buy a new spoiler from Rally Weld, at least I can get Saun to modify it to fit the arches.

 

[stuvy]

can you not cut/trim/shape/weld the front spoiler corners back on? what price is a brand new one against an afternoons work?

 

[rallyreturn]

can you not cut/trim/shape/weld the front spoiler corners back on? what price is a brand new one against an afternoons work?

Thought really hard about different ways to get it to fit and came up with a few Ideas that would work, but all required a fair bit of filler.

Called into Rally Weld on my way home from work and came away with a new spoiler £67. Not cheap, but not that expensive when you consider how much these cars cost to build these days.

Only down side is that it's going to take time and patience to fit as I've already matched it up to the front panel and it needs a fair bit of shaping.

I've just read a few threads on forums and everyone agrees that the spoiler is a bit of a pig to fit, but you have to get it at the right height.